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USER’S MANUAL

forfor

BLOCK PROVING WITH

AXLE COUNTER USING UFSBI

(IRS: S – 105/2012)

DELTRON EQUIPMENT & SYSTEMS PVT. LTD.26, CONVENT ROAD , KOLKATA-700014.Ph- (0091)(33)2265-1778. Works.- (0091)(33) 2217-6467.Tele-Fax - (0091)(33)2265-5903.E-mail – [email protected] www.deltron-india.com

Users Manual For Block Proving With Axle Counter using UFSBI For Double Line Ver No.: BPAC/UM/DL 1.0

Deltron Equipment & Systems Pvt. Ltd. Page No. 1 of 80

DOCUMENT DATA SHEET Specification IRS:S-105/2012 Version No.

BPAC/UM/DL 1.0

Title of Document USERS MANUAL FOR BLOCK PROVING WITH AXLE COUNTER USING UFSBI

Authors: Suparno Chatterjee Designation: Addl. Director

Approved by: Name: Mr. Sukrit Chatterjee Designation: Director, Technical (ISO-MR)

Abstract: This document described the functionality, installation & maintenance procedures of the equipment for Block Proving With Axle Counter using UFSBI manufactured as per IRS:S-105/2012



DOCUMENT CONTROL SHEET:

NAME ORGANISATION FUNCTION LEVEL Suparno Chatterjee

Deltron Equipment & Systems Pvt. Ltd.

Member

Prepare

Sukrit Chatterjee


ISO - MR

Approve

DOCUMENT CHANGE HISTORY:

VERSION NO. PUBLISHED BY DATE ALT. NO. BPAC/UM/DL 0.0


06.03.2006

-----

BPAC/UM/DL 1.0


04.08.2014

1. Specification no. changed from RDSO/SPN/188/2004 to IRS:S-105:2012



FOREW0RD

As the days are progress ing the technological advancement i s also taking place. With thi s advancement and from the experience, the Block Instrument Theory i s also gett ing changed for high-speed traff ic control . A system i s requi red to grant the Line Clear to an approaching train wi thin minimum poss ible lapse of t ime. As such Research Development & Standards Organisat ion of Rai lways formed a specif ication, which gives Line Clear to the approaching train with a f lawless veri f ication of the Block Sect ion status by the help of the Axle Counter. The system also helps the veri f ication of the part ing of t rain inside the Block Section. The L.V.V helps the Stat ionmaster to give the Line Clear to the other Train. With this method of ci rcuit designing Deltron Equipment & Systems Pvt. Ltd. has developed the Push Button type Block Instrument that could be commiss ioned with the Digi tal Axle Counter working with OFC. The detai l of the system i s descr ibed ins ide the manual.



CONTENTS

I Block Panel Page No 1. Mechanical structure -------------------------------------------- 6 2. Electrical Components ------------------------------------------- 6 3. Block telephone --------------------------------------------- 7 4. Quad Cable or Voice Channel ------------------------------- 7 5. Battery Set ------------------------------------------------------------ 7 6. Charger/Module of IPS-------------------------------------------- 7 7. Relay Rack and Signalling Relays ---------------------------- 7 8. Nomenclature of Relays For Double Line ------------------ 8 9. Wiring of Relay Rack ----------------------------------------------- 10 10. Indications on Block Panel -------------------------------------- 11 11. Brief System Description and Working ----------------------- 13 12. Description of Block Panel for Double Line ---------------- 13 13. Method of Signaling Trains from Block Station to

Block Station ---------------------------------------------------------- 15 14. Sequence of operation of Signalling a train

between 2 station -------------------------------------------------- 15 15. Refusal of Line Clear Enquiry ------------------------------------ 18 16. Closing Of Block after A Push Back Operation ----------- 18 17. Method of Push Back operation ------------------------------- 18 18. Block Back operation ---------------------------------------------- 19 19. Block Forward --------------------------------------------------------- 20 20. Shunting of Train ------------------------------------------------------- 22 21. Block Failures and Action To Be Taken ------------------------ 22 22. Technical Details of Block Equipment working with UFSBI - 26 23. Method of Line Clear Cancellation ----------------------------- 28

II Universal Fail- Safe Block Interface (UFSBI)

1. System Description. ------------------------------------------------- 29 2. UFSBI Hardware Architecture ---------------------------------- 30 2.1 DC-DC Converter --------------------------------------------------- 32

2.2 UFSBI –DS ---------------------------------------------------------------- 33 2.2.i INPUT Card ------------------------------------------------------ 34 2.2.ii CPU Card --------------------------------------------------------- 38 2.2.iii CC Card ---------------------------------------------------------- 38 2.2.iv OUTPUT Card ---------------------------------------------------- 39 2.2.v MODEM ----------------------------------------------------------- 39 2.2.vi Reset Box --------------------------------------------------------- 41 2.2.vii UFSBI Alarm Panel -------------------------------------------- 43 2.2.viii UFSBI Address Configuration Jumpers --------------- 45

3. UFSBI Installation Guide --------------------------------------------- 45 4. Installation Procedures ---------------------------------------------- 46 5. Maintenance ---------------------------------------------------------- 47



6. Do’s and Don’ts ------------------------------------------------------- 48 7. Error Code List and Recommended Action ---------------- 49

III List of Drawings

1. Block Section And Cable Plan ------------------------------------ 50 2. Block Panel (Face Plate) ------------------------------------------- 51 3. Block Panel (Mechanical)------------------------------------------- 52 4. Relay Rack Layout ---------------------------------------------------- 53 5. Contact Analysis Chart ---------------------------------------------- 54 6. Power Supply Arrangements --------------------------------------- 58

7. Line Circuit (Input) ---------------------------------------------------- 59 8. Line Circuit (Output) ------------------------------------------------- 60 9. Lines and Reset Box Circuit ----------------------------------------- 61 10. Push Button And Indication Circuit ------------------------------ 62 11. Relay Logic Circuit ---------------------------------------------------- 63 12. External Circuit ---------------------------------------------------------- 64 13. DAC Proving Relay Circuit Sending End ---------------------- 65 14. DAC Proving Relay Circuit Sending End ---------------------- 66 14. Relay Indication Circuit in the Relay Rack -------------------- 67

IV List of Annexure

A. Address configuration jumpers ------------------------------------ 68 B. Pre commissioning check-list --------------------------------------- 69 C. Error Code List ------------------------------------------------------------ 75 D. Details of quad cable connection ------------------------------- 79



I BLOCK PANEL 1. Mechanical Structure

The body of the Panel is made up of 18 SWG CRC-MS sheet (IS 513 Grade D) and is powdered coated with Siemens gray color. The mechanical dimension conformed to the Specification as laid down in IRS:S-105:2012.

Proper gasketting is done wherever required to prevent the ingress of water, dust, insects/pests etc.

Sealing arrangement with double locking is provided at the back door of the panel. The faceplate is made of MS 18 SWG (IS 513 Grade D) and is covered with anodized Aluminium facia with legends painted legibly on the faceplate as per specified in the drawing.

Faceplate of the Block Panel is covered with transparent acrylic sheet of 4mm thickness.

2. Electrical Components

The Panel is wired using 16/ 0.2 wire conforming to the specification IRS: S-76 / 89.

Terminals used in the block panel are non-disconnecting type Polymer (6.6 Polyamide/Nylon 6.6/ Melamine) based terminals of make Phoenix / WAGO with DIN rail mounting arrangements.

Push Buttons: The push buttons L&T make (ESBEE brand). Details of push buttons are given below:

Mushroom head push button actuator I. Red colour: Type- HD 55C 1 II. Black colour: Type- HD 55C 3 III. Yellow colour: Type- HD 55C 4 IV. Green colour: Type- HD 55C 2

Contact Element for Push Button and key actuator I. Type- HC61A2 (1NO) II. Type- HC61B2 (1NC)

Keys & Switches: The LCB key is L&T make (ESBEE brand) with catalog number HK85C3 for Key Actuator & HC61A2 (1 NO) / HC61B2 (1 NC) for Elements. The SM’s key is Siemens make with catalog number CES1 & for actuator.3SB04 00-0B for element.

LED: LED’s used are of high intensity super bright water clear type of Agilent make and have 5 mm diameter with a viewing angle of 15o.

Electromagnetic Impulse Counter: Electro magnetic impulse counter is of 6 Digit, 10 impulses per second minimum, 24V DC non-resetable type, Shinmei make, Type ECT-6A or Keltron Make, Type EM010 or , Fritz Kubler, Type W16.20



Buzzers: Cedicom or Piezo make buzzers (Continuous and Intermittent) working at 24 volts (+20% -10%) DC for audio alarm is provided to register the CALL ATTENTION BUZZER sent by other end SM & to register the occupation and clearance of each Block Section. The buzzer for receive line is intermittent and for dispatch line is continuous type. Provision to mute the audio alarm by pressing an acknowledgement push button is provided. The Block buzzer works through block telephone line.

3. Block Telephone

This is provided for speech communication with SM at other end of Block Section. Separate block telephone is provided for separate block section. Block Panel has provision for hanging block telephone as shown in Drg. No. RDSO /S 32017 Sheet no 3.

4. Quad Cable or Voice channel:

Provision for 2 and ½ quad or 4 voice channels (1 no. 4 wire & 3 nos. 2 wire) in OFC as shown in drg. No. RDSO/S32017 sheet no 1/3 is to be provided by the Railways. Cables will be as per specification TC 30/97.

5. Battery Set:

The Block Proving with Axle Counter system comprising of Block Panel, Universal Fail Safe Block Interface and the relays to work on 24 V D.C. with a maximum current consumption of 5A. Railways need to provide:

i. Separate power supply for Block Panel, UFSBI & relays ii. Separate power supply for Digital Axle Counter iii. Separate power supply for Block Telephone

(The complete power supply arrangement must be done in compliance with RDSO specification) 6. Charger / Module of IPS:

The charger will be as per IRS S-86 / 2000 to cater 5A/24V DC load. The IPS module as per RDSO SPN 165/2004 to cater 5A/24V DC load.

7. Relay Rack & Signaling Relays: All the relays used as per the circuit diagram are of RDSO approved make. Relay rack is housed inside the same UFSBI cabinet. The Electronic Fail Safe Timer (IRS: S 61/2000) is micro controller based. Relays are as per nomenclature described later in Para 8.



8. Nomenclature of relays for double line with UFSBI as per drawing

number- RDSO/S-32018. The nomenclature of various relays in the relay rack used at each station is given below:

SL. NO.

RELAY

TYPE AND NORMAL STATUS

DESCRIPTION

1.

TGTR QL1, 11F.4B DROP

Train Going To Relay. Operates to pick up on receipt of LINE CLEAR at train sending station. Normalizes, when station in advance sets to Line closed after train arrival or cancellation of LINE CLEAR.

2.

TCFR QL1, 11F.4B DROP

Train Coming From Relay. Operates to pick up on receipt of LINE CLEAR enquiry from train sending station. Normalizes after complete train arrival or cancellation of LINE CLEAR.

3.

ASCR

QN1, 8F.8B DROP

Advance Starter Signal Control Relay Picks up, when LINE CLEAR is available and necessary controls are reversed by SM. Drops in any of the under-mentioned cases: a) Entry of train in Block Section. b) Withdrawal of any SM control.

4.

TGTXR QN1,8F.8B DROP

Train Going To code Relay. Picks up at train sending station pressing of buttons for LINE CLEAR enquiry. Drops when train sending station releases buttons for LINE CLEAR enquiry or picking up of TGTR which ever is earlier.

5.

TGTYR QN1, 8F.8B DROP

Train Going To code Receive Relay. Picks up on receipt of LINE CLEAR at train sending station Drops in any of the under-mentioned cases: a) Entry of train in Block Section. b) Cancellation of Line Clear.

6. 120 JPR QN1, 8F.8B

DROP Timer mature repeater Relay. Picks up on maturity of Timer for cancellation. Drops when block status set to Line Closed.

7. BPNR QN1, 8F.8B

DROP Bell Push button Relay. Picks up on pressing of BELL push button with SM’s Key IN, else drops.

8. TGTNR QN1, 8F.8B

DROP Train Going To button Relay. Picks up on pressing of TRAIN GOING TO push button else drops.

9. CNR QN1, 8F.8B

DROP Cancel button Relay. Picks up on pressing of CANCEL push button else



drops.

10. FR1 QN1, 8F.8B

DROP Flash controller Relay No. 1. Toggles when Cancellation commenced or any other abnormal condition occur.

11. FR2 QN1, 8F.8B

DROP Flash controller Relay No. 2. Toggles when Cancellation commenced or any other abnormal condition occur.

SL. NO.

RELAY


DESCRIPTION

12. TAR1 QNA1, 8F.8B

DROP Train Arrival First Relay. Picks up when control on Reception Signal is Reverse and HS AT occupied by train and HS BT clear. Drops when AT clear with a delay.

13. TAR2 QN1, 8F.8B

DROP Train Arrival Second Relay. Picks up when control on Reception Signal is Reverse and HS AT is clear and HS BT occupied by train. Drops when block status set to Line Closed.

14. CAR QN1, 8F.8B

DROP Cancel relay. Picks up at Train receiving station on initiation of cancellation, provided all controls pertaining to Advance Starter and Reception Signal/Signals and signals controlled by them are at Normal at both the stations. Drops when cancellation matures and system goes to Line Closed condition.

15.

BTSR QN1, 8F.8B PICK UP

Block Track Stick Relay. Picks up when Block status is LINE CLOSED and Block track is clear. Drops in any of the under-mentioned cases: a) Entry of train in Block Section. b) Cancellation of Line Clear.

16. [R] AZTR

QNA1, 8F.8B PICK UP

Block Section track Relay of receive line. Drops in the under mentioned cases:

(a) Entry of train in block section, or (b) Axle Counter failure.

17.

[D] AZTR

QNA1, 8F.8B PICK UP

Block Section track Relay of dispatch line. Drops in the under mentioned cases:

(a) Entry of train in block section, or (b) Axle Counter failure

18. TGTZR QN1, 8F.8B

PICK UP Advance starter signal normal checking repeater Relay. Picks up to repeat Line Closed condition at train receiving station after arrival of train or after a Line Clear cancellation has been initiated, else drops.



SL. NO.

RELAY


DESCRIPTION

19.

TCFXR QN1, 8F.8B DROP

TRAIN COMING FROM code Receive Relay. Picks up on receipt of LINE CLEAR enquiry from train sending station. Drops when station in rear releases buttons for LINE CLEAR enquiry or TGTR pick up which ever is earlier.

20. 120 EJ Electronic

Time delay unit (Fail Safe)

Timer unit for cancellation time of 120 seconds.

21. HS ATPR

QNA1, 8F.8B PICK UP

First track for direction proving repeater Relay. Picks up when HSAT track circuit is vacant else drops.

22. HS BTPR

QNA1, 8F.8B PICK UP

Second track for direction proving repeater Relay. Picks up when HS BT track circuit is vacant else drops.

23. AS GNCR

QNA1, 8F.8B PICK UP

Advance Starter Signal Normal Checking Relay. Picks up when Advance Starter Signal and all its controls are at Normal, else drops.

24. HS GNCR

QNA1, 8F.8B PICK UP

Reception Signal Normal Checking Relay Picks up when Reception signal/signals and all its controls are at Normal, else drops.

25. AS GNCPR

QN1, 8F.8B PICK UP

Advance Starter Signal Normal checking (for other station) Relay Picks up when Advance Starter Signal and all its controls are Normal at the other station, else drops.

26. BIPR1 QN1, 8F.8B

TOGGLE UFSBI health checks Relay.

27. BIPR2 QN1, 8F.8B

TOGGLE UFSBI health checks Relay.

28. TCFCR QN1, 8F.8B

PICK UP Train Coming From Cancellation Relay. Picks up at receiving station when CANCEL CO OP button is pressed at sending station else drops.

29. BLR QN1, 8F.8B

DROP Bell Relay Picks Up When Other Station Presses the Bell Button

30. LFR O/E/N, 4R-3-

24 Link Fail Relay Picks Up When Both side UFSBI’s are healthy and communication link between them is established else drop.

31. Can CO-OPR

O/E/N, 4R-3-24

Cancellation Co-op button relay Picks Up at when Cancel Co-op button is pressed else drops. Placed in the SM block panel.

9. Wiring of Relay Rack:

I. The relay rack is wired using 16 / 0.2 wire conforming to specification IRS: S- 76 / 89 (latest).



II. Every wire is terminated properly. Termination of wires is done on non-disconnecting type terminals of Phoenix / Wago make with DIN rail mounting arrangements.

III. Individual termination is marked with a unique number for easy identification. IV. Wiring of relay rack is properly bunched.

10. Indications on Block Panel: SM’s Block Panel for Double Line is provided with following illuminated indications

LINE CLOSED Indicat ion

YELLOW

Circular indications (Two Numbers) in between the directional arrowhead. To indicate Block Section free from vehicles and LINE CLEAR not granted / received at train receiving / train sending station respectively.

TRAIN COMING FROM Indicat ion

a) GREEN

b) FLASHING GREEN

In a directional arrowhead pointing downward for incoming traffic at train receiving station and a rectangular indication named TCF To indicate LINE CLEAR granted, when TRAIN GOING TO Button and BELL button have been pressed at sending station and the conditions for the granting of LINE CLEAR at receiving station have been complied with.

To indicate: a) Block section clear after arrival of train, but

associated Signals and their controls are not normal at either station or the LCB Key is OUT.

b) Cancellation of LINE CLEAR before entry of train in Block Section.

TOL indicat ion In a directional arrowhead pointing downward and a rectangular indication for incoming train at receiving station.

RED To indicate TRAIN ON LINE on entry of incoming train

on LINE CLEAR.



TRAIN GOING TO Indicat ion a) GREEN

b) FLASHING GREEN

In a directional arrowhead pointing upward for outgoing traffic at train sending station and a rectangular indication named TGT To indicate LINE CLEAR granted, when TRAIN GOING TO Button and BELL button have been pressed at sending station and the conditions for taking the LINE CLEAR have been complied with at both stations.

To indicate: a) Block section clear after arrival of train, but

associated Signals and their controls are not normal at either station or the LCB Key is OUT at receiving station.

b) Cancellation of LINE CLEAR before entry of train in Block Section.

TOL indicat ion

RED

In a directional arrowhead pointing upward and rectangular indication for outgoing traffic at the train sending station. To indicate TRAIN ON LINE on entry of outgoing train on LINE CLEAR.

Cancel CO-OP indicat ion

YELLOW

Indication to indicate co-operation extended by station at other end for cancellation of line clear by pressing Cancel Cooperation button.

CANCEL indicat ion

FLASHING YELLOW

STEADY

YELLOW

Circular LED.

To indicate progress of LINE CLEAR cancellation timer of 120 seconds. The indication lights up on pressing of CANCEL Button along with BELL button when, TRAIN COMING FROM displays with FLASHING GREEN indication.

To indicate Cancellation timer matures but due to some reason the system does not go to Line Close.

SNK Indicat ions

YELLOW

Two such indications are provided. i) SNK (D): Yellow indication provided near TRAIN GOING TO directional arrowhead to indicate LAST STOP SIGNAL and its controls at ON / Normal. ii) SNK (R): Yellow indication provided near TRAIN COMING FROM directional arrowhead to Indicate reception signal (s) & its controls at ON / Normal

SNOEK (SNK other end)

YELLOW

i) Provided near TRAIN COMING FROM directional arrowhead to Indicate LAST STOP SIGNAL and its controls at the station in rear are at ON / Normal.

Last Stop S ignal (LSS)

RED

GREEN

Circular in monogram of signal.

To indicate Last Stop Signal is at ‘ON’

To indicate Last Stop Signal is at ‘OFF’



LINE FREE indicat ion GREEN

An indication is provided near the arrowhead indication to show Block Section is clear of vehicles.

LINE OCCUPIED indicat ion RED

An indication is provided near the arrowhead indication to show Block Section is occupied.

ACKN indicat ion YELLOW

An Indication near ACKN button. To indicate SECTION buzzer ON status

SM KEY `IN' indicat ion

GREEN

Indication near SM KEY.

To indicate SM key “IN’. UFSBI/MUX OK indicat ion

GREEN when MUX is OK otherwise extinguished.

UFSBI/MUX FAIL indicat ion

RED when MUX goes into a failure mode otherwise extinguished.

Communicat ion L INK FAIL indicat ion

Steady YELLOW when LINK FAILS else flickering.

11. Brief System Description & Working:

The Block Panel work in Absolute Block system incorporating Block Proving by Axle Counter to control the movement of trains on double line block section from one block station to another in a fixed direction. These working instructions are in conjunction with General Rules (GR) of 1976 and its amendment in 2002. These working instructions do not supersede any rule laid down in GR.

Principle of working The trains are worked on Absolute Block system Each block section is provided with an Axle Counter to verify the occupation

or clearance of block section and indicated on Block Panel It is not possible to obtain Last Stop Signal to ‘OFF’ unless LINE CLEAR has

been obtained from the station in advance It is not possible to take LINE CLEAR unless block section and an adequate

distance beyond first stop signal of station in advance is clear of trains The Last Stop Signal assumes ‘ON’ aspect automatically on entry of train into

block section and when so replaced, is maintained in its ‘ON’ position, till a fresh LINE CLEAR is obtained on block panel

Block section show automatically Train on Line on panel when train enters into the block section on line clear.

Train entry/exit buzzer, to/ from block section are provided and to be acknowledged

Block section automatically closes on complete arrival of train at the receiving station

A control to prevent the station in rear to take LINE CLEAR on its Block Panel without taking consent of receiving station.



A control to cancel the LINE CLEAR, already taken by station in rear. It is possible to close the block section only, if no trains have entered the

Block Section for at least 120 seconds after application of cancellation with co-operation from station in rear

12. Description of Block Panel for Double line SM’s Block Panel is provided with following KEYS for various functions.

SM key SM/ASM/Switchman’s control key. The key when out prevents the following operations: a) Transmission of Call attention buzzer b) Transmission of IS LINE CLEAR enquiry request c) Cancellation of LINE CLEAR

LCB key LINE CLEAR BLOCKING key. It serves the following, when out, To prevent station in rear to take LINE CLEAR. To prevent closing of Block

SM’s Back Cover lock Key

To open or lock the back cover by SM/ASM/Switchman, when required by signal staff for maintenance or repairs.

Maintainer Back cover lock key

To open or lock the back cover by authorized signal staff, for maintenance or repairs, provided SM’s back cover lock key.

SM’s Block Panel is provided with following PUSH BUTTONS (non-locking type) & COUNTERS

BELL button (Black in colour)

To transmit Call attention buzzer to station at other end of Block section.

To take LINE CLEAR, when pressed along with TRAIN GOING TO button. To cancel LINE CLEAR, when pressed along with CANCEL button.

TRAIN GOING TO Button (Red in colour)

To transmit IS LINE CLEAR enquiry to station in advance for taking LINE CLEAR. It is used in conjunction with BELL button at train sending station to light up TRAIN COMING FROM (GREEN) indication on Block Panel of receiving station, which in turn automatically grants LINE CLEAR to light up and TRAIN GOING TO (GREEN) indication on Block Panel of sending station.

ACKN button(s) (Black in Colour)

Two such buttons are provided, one each for despatch line and receive line. To mute the SECTION buzzer on occupation or clearance of

block section. Cancel Co-op Button (Green in colour)

To give co-operation from sending station to cancel the line clear at receiving station.



CANCEL Button (Yel low in colour)

It is used in conjunction with BELL button at train receiving. Station under following conditions: a) There is no Train in the block section and Line clear

cancellation needs to be done. b) Complete train has been pushed back at train sending

station. Cancellat ion Counter

To register cancellation of line clear.

13. Method of Signalling Trains from Block Station to Block Station a) SM of the station intending to send a train from his station obtains verbal consent over

block telephone from station in advance before taking LINE CLEAR on its Block Panel. b) Before a request for IS LINE CLEAR is sent to station in advance, SM of sending station

ensures the following near TRAIN GOING TO arrowhead on its Block Panel; i) LINE CLOSED indication YELLOW, ii) LINE FREE indication GREEN & iii) SNK indication YELLOW. iv) UFSBI / Mux OK indication GREEN v) Communication Link fail Extinguished

c) The station in advance while granting his verbal consent ensures the following near

TRAIN COMING FROM arrowhead on its Block Panel; i) LINE CLOSED indication YELLOW, ii) LINE FREE indication GREEN, iii) SNK indication YELLOW, iv) SNOEK indication YELLOW & v) UFSBI / Mux OK indication GREEN vi) Communication Link fail Extinguished

The SM then inserts and turns LCB key. d) Thereafter SM of sending station presses BELL & TRAIN GOING TO buttons. e) The arrowhead, TRAIN GOING TO/ TRAIN COMING FROM is lit up to green at

sending/receiving station respectively. f) SM of sending station releases BELL & TRAIN GOING TO buttons on getting TRAIN GOING

TO green indication. g) The sending station SM after obtaining LINE CLEAR on its Block Panel sends the train into

Block Section by taking the LSS to `OFF'. On entry of train into section, TRAIN ON LINE lights up RED at both the stations in arrowhead indication. SECTION buzzer sounds at both the stations along with ACKN indication near respective ACKN button. Pressing of ACKN button of corresponding line (Despatch/Receive) will turn off the buzzer and the ACKN indication.

h) After receipt of train at receiving station proper reception signals and complete arrival

of train, TRAIN GOING TO /TRAIN COMING FROM arrowhead indication turns to FLASHING GREEN & LINE FREE indication turns to GREEN at both the stations. TRAIN GOING TO /TRAIN COMING FROM indication continues FLASHING GREEN at sending /



receiving station respectively until reception & departure signals and their controls are not normal or LCB Key is not `IN'. If reception & departure signals and their controls are at normal & LCB key is IN, TRAIN GOING TO /TRAIN COMING FROM arrowhead indications turns off and yellow LINE CLOSED indication lights up yellow.

14. Sequence of operations of signalling a train between two stations

If the block section is clear and the ‘LINE CLOSED’ indication is displayed on Block Panel at both the stations, the action is taken by the sending station SM as under:

SENDING STATION RECEIVING STATION 1. SM ensures

LINE CLOSED indication YELLOW, SNK indication YELLOW, SNOEK indication YELLOW, LINE FREE indication GREEN UFSBI / Mux OK indication GREEN Communication Link fail Extinguished

2.

SM inserts SM key & turns to IN. a) SM sends ‘Call Attention’ signal

to receiving station by pressing BELL button.

SM inserts SM key & turns to IN (a) SM acknowledges the ‘Call Attention’ signal by pressing BELL button.

3. SM sends ‘Attend Telephone’ signal by pressing BELL button.

4. SM acknowledges by pressing BELL button and attends telephone.

5. SM attends telephone and advises station in advance about the intended movement of the train on telephone & asks for LINE CLEAR

6. d) Exchanges information regarding train movement and ensures LINE CLOSED indication YELLOW, SNK indication YELLOW, SNOEK indication YELLOW, LINE FREE indication GREEN

UFSBI / Mux OK indication GREEN Communication Link fail Extinguished & Turn LCB Key IN e) Grants verbal LINE CLEAR.

7. SM presses BELL & TRAIN GOING TO buttons until ‘TRAIN GOING TO’ arrowhead indication lights up GREEN. (If aforesaid indicator does not appear after 3 seconds (approx.) of pressing the buttons, SM releases the buttons and rechecks conditions at his station and asks station at other end to recheck the conditions for granting of LINE CLEAR.)

8. ‘LINE CLOSED’ indicator turns off and ‘TRAIN COMING FROM’ arrowhead indication lights up GREEN.



SENDING STATION RECEIVING STATION 9. ‘LINE CLOSED’ indicator turns off.

‘TRAIN GOING TO’ arrowhead indication lights up GREEN. Releases BELL & TRAIN GOING TO buttons.

10 Takes LSS to ÒFF'. Train enters the Block Section.

11

LSS replaces to ‘ON’.

LINE OCCUPIED indicator turns to RED. SECTION buzzer sounds & ‘TRAIN GOING TO’ arrowhead indication turns RED. ACKN indication lights up. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

LINE OCCUPIED indicator turns to RED . SECTION buzzer sounds & ‘TRAIN COMING FROM’ arrowhead indication turns RED. ACKN indication lights up. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

Puts back the LSS controls to Normal.

Ensures SNK lights up YELLOW. SNOEK lights up YELLOW Takes reception signal ÒFF' to receive the train. Train passes Home Signal. Home Signal replaces to ÒN'. Train clears the Block Section including Block overlap

13 SECTION buzzer sounds. ACKN indication lights up YELLOW. LINE FREE indicator turns to GREEN. `TRAIN GOING TO' arrowhead indication turns to FLASHING GREEN. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

12 SECTION buzzer sounds. ACKN indication lights up YELLOW & LINE FREE indicator turns to GREEN. ‘TRAIN COMING FROM’ arrowhead indication turns to FLASHING GREEN. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

15 SNOEK indication lights up YELLOW.

14 Replaces all controls pertaining to reception of train to Normal. SNK indication lights up YELLOW.

`TRAIN GOING TO' arrowhead indication turns off. `LINE CLOSED' indication lights up.

`TRAIN COMING FROM’ arrowhead indication turns off. ‘LINE CLOSED’ Indication light up.



15. Refusal to ‘Line Clear Enquiry’

When the line is being blocked by the presence of a train in the section or train parting, or shunting or opening of level crossing in mid section or for any other reason, the LCB key is taken out and kept in safe custody. On removal of obstruction, SM immediately informs SM in rear about the fact. Puts LCB Key IN so as to enable him to send a fresh IS LINE CLEAR enquiry.

16. Closing of Block after a “Push Back” operation

After a train has been pushed back at the sending station, the sending station advises the receiving station. The receiving station closes the section by pressing BELL and CANCEL button after getting cooperation from the sending station.

17. Method of “Push back” operation

SENDING STATION RECEIVING STATION 1. Train clears the Block Section. LINE

FREE indicator turns GREEN. SECTION buzzer sounds. ACKN indication lights up.

2. Train clears the Block Section. LINE FREE indicator turns GREEN. SECTION buzzer sounds. ACKN indication lights up.

‘TRAIN GOING TO’ arrowhead indication turns to FLASHING GREEN.

‘TRAIN COMING FROM’ arrowhead indication turns to FLASHING GREEN.

Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off. Ensures that the SNK indication is YELLOW

Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

3. Advises other end station SM to close the Block, on telephone after Call attention buzzer sounds.

4. On request from sending station SM about closing of the Block, on telephone, after Call attention buzzer sounds. Ensure SNK indicator YELLOW, SNOEK indicator YELLOW,

5. After verbal consent from other end SM Ensure SNK indication YELLOW, SNOEK indication YELLOW, Presses CANCEL CO-OP button and releases on receipt of Call attention buzzer.

6. CO-OP indication turns YELLOW. Presses BELL & CANCEL button with SM key IN. CANCEL COUNTER increments. CANCEL indication turns FLASHING YELLOW & continues flashing for 120 seconds.

8. TRAIN GOING TO arrowhead indication turns off. LINE CLOSED indication glows.

7. On expiry of 120 seconds, TRAIN COMING FROM arrowhead indication and CANCEL indication turns off. ‘LINE CLOSED’ indication glows.



18. Block Back Operation The SM, who intends to Block Back the line, informs the SM of station in rear on telephone for permission to Block Back, who acknowledges the message and grants permission supported by a private number. SM takes LCB key OUT and keeps in safe custody. The SM will then issue necessary authority to driver of train to perform shunting in Block Section. On completion of shunting, section clear message will be sent to SM of station in rear on telephone about obstruction removed supported by a private number, who in turn will acknowledge the same supported by a private number. Thereafter SM will insert LCB key and turn to `IN' position. All the entries in Train Signal Register (TSR) for this operation is made in RED ink. The reasons for Block Back shall be recorded in remarks column against each entry.

Station in REAR Station intending BLOCK BACK 2. Block Panel displays;

LINE CLOSED - YELLOW LINE FREE - GREEN SNK - YELLOW

1. Block Panel displays; LINE CLOSED - YELLOW LINE FREE - GREEN SNOEK - YELLOW

4. Acknowledges call attention / attend telephone signal.

3. Inserts SM key & turns ‘ON’ Gives call attention / attend telephone signal.

6. Attends telephone. 5 Attends telephone. 8. Acknowledges & gives consent by

private number. 7 Inform intention to perform shunting in

Block Section. 9 Takes LCB Key 'OUT' and keeps in safe

custody. Issue necessary authority to driver of train to perform shunting in Block Section.

11. On entry of train in Block Section, SECTION buzzer sounds & ACKN indication glows.

10. On entry of train in Block Section, SECTION buzzer sounds & ACKN indication glows.

LINE OCCUPIED indication turns to RED. LINE CLOSED indication turns off

LINE OCCUPIED indication turns to RED. LINE CLOSED indication turns off.



13. On clearing of Block Section. SECTION buzzer sounds & LINE CLOSED indication lights up. ACKN indication lights up.

12. On clearing of Block Section. SECTION buzzer sounds & LINE CLOSED indication glows. ACKN indication lights up.

LINE FREE indication turns to GREEN. LINE CLOSED indication turns YELLOW.

LINE FREE indicator turns to GREEN. LINE CLOSED indication turns YELLOW.



Station in REAR Station intending BLOCK BACK Acknowledges the buzzer by

pressing ACKN button. ACKN indication turns off.


15. Acknowledges call attention /attend telephone signal.

14. On completion of shunting, SM verifies the line between opposite STARTER (if any)/ Shunt signal or Block Section Limit Board, Stop Board/ Fouling mark and First Stop Signal free from any vehicle. Gives call attention / attend telephone signal.

17. Attends telephone. 16. Attends telephone.

19. Acknowledges supported by the private number.

18. Inform shunting is completed supported by a private number.

20. Inserts LCB KEY & turns to `IN'.

19. Block Forward

The SM, who intends to Block forward the line, shall inform the SM of station in advance on Telephone for permission to Block forward, who will acknowledge the message and grant permission supported by a private number. The SM of advance station takes LCB key OUT and keeps in safe custody. The SM of this station will then issue necessary authority to driver of train to perform shunting in Block Section. On completion of shunting, message will be sent to SM of station in advance on telephone about obstruction removed supported by a private number, who in turn will acknowledge the same supported by a private number. Thereafter SM of advance station will insert LCB key and turn to IN position. All the entries in Train Signal Register for this operation should be made in RED ink. The reasons for Block forward shall be recorded in remarks column against each entry.



Station intending BLOCK FORWARD Station in advance 1. Block Panel displays;

LINE CLOSED – YELLOW LINE FREE – GREEN

2. Block Panel displays; LINE CLOSED – YELLOW LINE FREE – GREEN

3. Inserts SM key and turns, Gives call attention /attend telephone signal.

4. Acknowledges call attention / attend telephone signal.

5. Attends telephone. 6. Attends telephone. 7. Inform intention to perform shunting

in Block Section. 8. Acknowledges and gives consent by

private number. 10. Issue necessary authority to driver of

train to perform shunting in Block Section.

9. The LCB Key is taken out and kept in safe custody.

11. On entry of train in Block section, SECTION buzzer starts ringing and LINE CLOSED indication turns off. ACKN indication lights up. LINE FREE indication turns to RED. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

12. On entry of train in Block section, SECTION buzzer starts ringing and LINE CLOSED indication turns off. ACKN indication lights up Yellow. LINE FREE indication turns to RED. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

13. On clearing of Block Section. SECTION buzzer starts ringing and LINE CLOSED indication lights up yellow. ACKN indication lights up Yellow. LINE FREE indication turns to GREEN. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

14 On clearing of Block Section SECTION buzzer starts ringing and LINE CLOSED indication lights up. ACKN indication lights up yellow. LINE FREE indication turns to GREEN. Acknowledges the buzzer by pressing ACKN button. ACKN indication turns off.

15. On completion of shunting, SM verifies the line between STARTER /Shunt signal/Stop Board/fouling mark and LAST STOP SIGNAL, free from any vehicle. Inserts SM key and turn. Gives call attention to attend telephone.

16. Acknowledges call attention to attend telephone.

18. Attends telephone. 17. Attends telephone. 20. Inform shunting is completed

supported by a private number.

19. Acknowledges supported by a private number.

21. Inserts LCB and turn in.



20. Shunting of train Where shunt signals are not provided for shunting on line leading towards Block section, the driver of shunting train shall be given shunting order at the foot of STARTER SIGNAL /STOP BOARD/FOULING MARK before allowing any shunting.

Shunting of Train up to Last Stop Signal

While shunting, on dispatch line the LAST STOP SIGNAL is to be kept at ‘ON’. SM KEY is taken OUT. The driver of shunting train is given shunting order to shunt up to LSS. On completion of shunting, the line between STARTER/ Shunt Signal/ Stop Board/ Fouling mark and LSS are checked free from any vehicle. SM KEY is inserted and turned to IN position.

Shunting behind a train Shunting behind a train is performed with a message to a station in advance. The station in advance takes LCB Key out and kept in safe custody. Shunting is performed as per previous para. On completion of shunting, SM of sending station verifies the line between STARTER/Shunt Signal/Stop Board /fouling mark and LAST STOP SIGNAL free from any vehicle. The message regarding completion of shunting is sent to station in advance. SM of station in advance inserts LCB Key and turns to IN position.

Shunting Of Train Beyond Last Stop Signal

The shunting is done under protection of Block Forward only.

Shunting Of Train Towards First Stop Signal The shunting is done under protection of Block Back only.

Shunting Of Train in face of an approaching Train

No shunting in face of approaching train, towards receive line is permitted, until the approaching train has been brought to a stop at first stop signal of the station. Whenever such shunting is performed, LCB Key is taken OUT and kept in safe custody. The driver of shunting train is given shunting order to FIRST STOP SIGNAL. On completion of shunting, the line between STARTER/SHUNT SIGNAL/STOP BOARD /FOULING MARK AND FIRST STOP SIGNAL are checked free from any vehicle and only then LCB key is inserted and turned to IN position.

21. Block failures and action to be taken:

The block failures can be categorized into the following:

Failure of BLOCK PANEL Block panel is considered to be defective for UP and DOWN trains , as the case may be and can not be restored for normal working until tested by



competent signal staff & certified fit by them for use after the under-mentioned cases except for the case of Communication Link Failure (steady yellow indication). After the Communication Link Failure indication becomes flickering again block panel operation can be restored.

SL.

NO. CAUSE OF FAILURE ACTION TO BE TAKEN

1. When no indication of any sort, at all

appears on the block panel or;

Block Panel should be treated as defective block working suspended & trains are to be dealt with by taking LINE CLEAR on the electrical communication equipment provided and by provisions of GR 14.13 & SR there under, if any.

2. When the Call attention buzzer signals are received indistinctly or;

-do-

3. Any damage is seen or reported to block panel or;

-do-

4. When none of the indications viz. ‘TRAIN COMING FROM and TRAIN GOING TO’ appears on the block panel except ‘LINE FREE’ or;

5. When no train has entered into the block section but the ‘LINE OCCUPIED’ indication lights on RED on both lines and these indication persists even after resetting of the Axle Counters have been tried. or:

-do-

6. When a train has arrived at the receiving station but the Block Panel still shows ‘TRAIN ON LINE’ RED indication and persist on both lines or;

-do-

7. When BI Fail indication comes. or;

-do-

8. When Link Fail indication becomes steady yellow. or;

-do-

9. When ‘TRAIN GOING TO’ or ‘TRAIN COMING FROM’ Arrow Head Indications do not appear by appropriate action though condition for asking ‘LINE CLEAR’ and granting permission to approach are available. or;

-do-



10. TRAIN GOING TO or TRAIN COMING FROM Arrow Head Indications does not turn to RED to give TRAIN ON LINE on the entry of train into Block Section at either of the stations or;

-do-

11. When a train has arrived at the receiving station but the Block Panel shows FLASHING GREEN/GREEN indication even after ensuring SNK indication and LCB key IN or;

In addition to action taken for case 1-10, all efforts should be made to keep the LAST STOP SIGNAL at ON position. If it is not possible, then a competent railway servant should be deputed with RED hand signal at the foot of the LAST STOP SIGNAL to warn the drivers of the approaching trains. In addition all trains in the relevant direction should be stopped at Home signal and after ensuring that they have come to a stop, the Home signal should be cleared to caution aspect only.

The STARTER signal should not be taken OFF until the issue of relevant authority to pass the STARTER and LAST STOP SIGNAL to the driver. Caution order should also be issued to the driver about the defect of LAST STOP SIGNAL.

12. When, after a cancellation, CANCEL indication does not light up FLASHING YELLOW or STEADY YELLOW after appropriate actions

13. When Last Stop Signal cannot be kept at ‘ON’ during its suspension /disconnection.

14. When Last Stop Signal of the station does not go back to ‘ON’ position on the entry of a train into the Block Section

15. Total failure of communication during which train shall be worked as per extent rules in force on the Railway

In addition to action taken for case 1-14, the trains should be dealt with under the extent rules as outlined in GR 14.13 and SR there under

Failure Of Last Stop Signal & Action To Be Taken

Sl.

No. Cause of failure of the LSS Action to be taken

1. When it cannot be taken OFF even

though LINE CLEAR has been obtained; or;

The LAST STOP SIGNAL should be considered to have failed and failure shall be informed to Signal staff immediately. The LINE CLEAR shall be obtained on the BLOCK PANEL and Line Clear ticket/Paper line clear as prevalent on railway shall be issued to driver of train



Sl.

No. Cause of failure of the LSS Action to be taken

2. When it can be cleared without

obtaining LINE CLEAR; or; The LAST STOP SIGNAL should be considered to have failed and failure shall be informed to Signal staff immediately and follow failure of Block Panel Para 13 & 14

3. It do not restore to ON position on entry of train into Block Section.

The LAST STOP SIGNAL should be considered to have failed and failure shall be informed to Signal staff immediately and follow failure of Block Panel Para 13 & 14

Suspension Of Block Working & Action To Be Taken

Cause of Suspension Action to be taken

1. When material lorries, or Motor trolley, or

Tie-tamping machines, or Rail Motor/Bus or rail cum road vehicles or Tower wagon (4 wheeler) has to run in the section.

BLOCK PANEL shall be suspended for respective line and these vehicles shall be worked on PAPER LINE CLEAR.

2. An accident takes place in the mid section.

BLOCK PANEL shall be suspended, for both lines if line adjacent to affected line is reported to be infringed, till the infringement exists for dispatch line or; LSS shall be treated as INOPERATIVE & FAILED.

3. When any part of Block Panel is opened or removed for repairs under duly accepted disconnection notice.

BLOCK PANEL shall be suspended. LSS shall be treated as INOPERATIVE & FAILED.

4. When Last Stop Signal of the station has been disconnected by Signal staff for repair.

LSS shall be treated as INOPERATIVE & FAILED.

5. During Block FORWARD. LSS shall be treated as INOPERATIVE & FAILED.

When the cause of suspension of BLOCK PANEL and/or LSS is removed, the normal working of BLOCK PANEL / LSS, as the case may be shall be restored by SM.



22. Technical details of Block equipment working with UFSBI: TO DISPATCH A TRAIN

AT SENDING STATION AT RECEIVING STATION The fol lowing relays are normal ly energized in L INE CLOSED ASGNCR , [D] AZTR The fo l lowing indicat ions appear in the block panel L INE CLOSED – Yel low, SNK-Yel low, SNOEK-Yel low, L INE FREE – green, , Last S top S ignal – Red

The fol lowing relays are normal ly energized in L INE CLOSED BTSR , HSATPR , HSBTPR , HSGNCR , [R]AZTR , ASGNCPR , The fo l lowing indicat ions appear in the block panel L INE CLOSED –Yel low, SNK-Yel low, SNOEK-Yel low, L INE FREE-Green, , Last S top S ignal – Red

1 a) The SM at sending station inserts its SM key and turns to IN position. SM Key - Green. b) Presses BELL button. BPNR and TRAIN GOING TO

button. TGTNR. c) TGTXR relay picks up,

provided the conditions for receiving LINE CLEAR exist and transmits LINE CLEAR enquiry.

Waits for ‘TRAIN GOING TO” Indication to light up GREEN.

2 a) TCFXR picks up.

b) TCFR operates and latches, provided the conditions for granting LINE CLEAR exist. c) ‘LINE CLOSED’ turns ‘OFF’. d) TCFK (G) “TRAIN COMING FROM” indication GREEN turns ‘ON’. d) Sends LINE CLEAR granted code.

3 a) TGTYR picks up. b) TGTZR. c) TGTR picks up and latches

and TGTXR. d) “LINE CLOSED” indication

turns ‘OFF’. e) TGTK (G) “TRAIN GOING TO”

indication lights up GREEN. f) Releases BELL and TRAIN

GOING TO buttons. BPNR TGTNR.

g) Advance Starter signal can be taken ‘OFF’ by SM control. ASGNCR ASCR, SNK OFF, LSS - Green.

4 TCFXR. ASGNCPR, SNOKE extinguished.

5 a) Train enters Block Section ASCR, AZTR, BTSR. b) LINE OCCUPIED indication

turns RED.

6 a) Train enters Block Section. b) AZTR, BTSR.



c) TGTK (G) indication changes to TGTK(R). LSS – Red.

d) SECTION Buzzer sounds with indication near ACKN button.

e) SM presses ACKN to silence the SECTION buzzer and turn ‘OFF’ aforesaid indication.

f) TGTYR. g) Restores all Signal controls to

Normal. ASGNCR, SNK-Yellow h) Train in section.

c) LINE OCCUPIED indication turns RED.

d) TCFK (G) indication changes to TCFK(R).

e) SECTION Buzzer sounds with

indication near ACKN button. f) SM presses ACKN to silence the

SECTION buzzer and turn ‘OFF’ aforesaid indication.

g) ASGNCPR, SNOKE- YELLOW. h) Train in section.

7 a) Train is received by reversing the Home Signal Lever,

HSGNCR, SNK- ‘OFF’. b) Train occupies HSAT, HSATPR, TAR1 and sticks. c) Train occupies HSBT, HSBTPR and

clears HSAT, HSATPR TAR2 and sticks.

d) TAR1. e) AZTR, Line Free Green. f) SECTION Buzzer sounds with

indication near ACKN button. g) SM presses ACKN to silence the

SECTION buzzer and turn ‘OFF’ aforesaid indication.

h) FR1 and FR2 operate to give flashing indications.

i) TCFK(R) changes to TCFK (flashing green).

8. a) AZTR. b) LINE FREE indication turns GREEN. c) FR1 and FR2 operate to give flashing indications. d) TGTK(R) changes to TGTK (flashing green).

9. a) Normalizes all controls to pick up HSGNCR. b) Waits for TGTZR to pick up and on its pick up, de-latches TCFR. c) BTSR. d) LINE CLOSED indication turns ON. e) TCFK (flashing green) turns OFF.

10 a) TGTR, TGTZR. b) LINE CLOSED indication turns ON. c) TRAIN GOING TO (Flashing Green) indication turns OFF.



23. Method Of Line Clear Cancellation

After a train sending station has taken line clear, the receiving station can carry out line clear cancellation with the consent of other end station. Sending station puts back LSS to “ON”, if already taken “OFF” and its control to normal ensures SNK at “YELLOW”. Sending station extends co-operation by pressing CANCEL CO-OPERATION button. On receipt of co-operation indication, receiving station presses bell and cancel button with SM KEY “IN”. Receiving station observes cancel indication to light up flashing yellow and releases the buttons. TRAIN GOING TO/ TRAIN COMING FROM Arrow Head Indication turns to flashing green at sending/ receiving station respectively. After 120 seconds LINE CLOSED indication lights up “YELLOW”. TRAIN GOING TO/ TRAIN COMING FROM Arrow Head Indication and cancel indication extinguishes. Method of Cancellation

SENDING STATION RECEIVING STATION 1. PUTS back LSS to `ON’, if already

taken `OFF, ensures SNK at YELLOW, Advises receiving end station SM about cancellation on telephone after Call attention buzzer sounds.

2. Agrees to request, ensures SNK at YELLOW and SNOEK at YELLOW and gives consent on telephone after Call attention buzzer sounds

3 After verbal consent from other end SM, presses cancel co-operation button and releases on receipt of Call attention buzzer.

4. Waits for co-operation light up yellow and presses, bell & cancel button with SM key IN. Cancel counter increments. TRAIN COMING FROM indication turns to flashing green. Cancel indication lights up flashing yellow & continues flashing for 120 seconds.

5. ‘TRAIN GOING TO’ indication turns flashing green.

7. ‘TRAIN GOING TO’ Indication turns off LINE CLOSED indication lights up.

6. On expiry of 120 seconds, TRAIN COMING FROM Indication & cancel indication turns off. LINE CLOSED indication lights up.



II) UNIVERSAL FAIL-SAFE BLOCK INTERFACE (UFSBI) 1. System Description The system requirement specification of the “Universal Fail-safe Block Interface (UFSBI)” equipment has been described in RDSO specification SPN/147/97 (Annexure A). The functionalities are elaboration of the general requirements contained RDSO specification SPN/147/97. The environment conditions under which the system will operate are described in SPN/147/97. General: The UFSBI system acting as multiplexer for communicating the commands to one block panel to other in a fail safe manner to transfer block instrument signals (DC and analog FM signals converted to status) to the other end. The communication is full duplex. The medium of communication is digital channels of Optical fiber, copper cable or microwave radio (Through RS232 Serial Port). The mux with its accessories, Interlocking relays and power supply are housed in a cubicle, called UFSBI-Cubicle. Technical: a) The equipment is capable of driving safety-signaling relays conforming to

specification BRS: 930 (Q – Series relays). b) The equipment is capable of working on Quad Cable as per TC 30/97 as well as

Voice/Data Channel provided over Optical Fibre. c) The coding of signal transmission takes care of types of noise generally

encountered in the transmission system and ensures safety of operation against these noises.

d) Each equipment in the section has a unique address, which is settable through back-panel jumpers. Please refer “UFSBI Address Configuration Jumpers” given later in this manual.

e) The information exchanged between the pair of the interface equipment contains the source & destination address.

f) Wrongly addressed information packets are promptly rejected by the system and frequent receipt of such packets is detected as link failure by the system.

g) The telephone will work on a separate voice channel. h) The system works on 24V DC + 20% - 10%. i) A push button is provided for resetting UFSBI inside the cubicle on a reset box.

The resetting system is provided with a veeder counter to count the number of reset action.

2. UFSBI Hardware Architecture: 1. DC-DC Converter 2. UFSBI-DS 3. Relay Rack



DC – DC CONVERTER

UFSBI - DS

RELAY RACK

UFSBI FRONT VIEW

BIPR1

T I M E R

T G T X R

TGT R

ASGNCR

HSGNCR

TCFR

FR1

BIPR2

LFR

T CF X R

T CFCR

T GT YR

ASGNCPR

T GT Z R

BL R

FR2

CAR

BTSR

TAR2

TAR1

HSBTPR

HSATPR

[D] A Z T R

CNR

TGTNR

ASCR

120JPR

BPNR

[R] A Z T R



DC – DC CONVERTER

WAGO BOARD

B24V BUS BAR

SPIKE BUSTER

MCB

EXTERNAL TERMINAL (E1- E150)

MODEM

RESET BOX

MOTHER BOARD

UFSBI BACK VIEW

N24V BUS BAR

FUSE TERMINAL (F1, F2, F3, N)

PANEL TERMINAL (P1 - P45)

VERSION DISPLAY

SPD

PMSS

MODEM LINE TERMINAL

BLOCK TELE LINE TERMINAL

BLOCK TELE POWER TERMINAL



The functionalities of each part is Described Below II.2.1. DC-DC Converter :-

DC – DC Converter Front View DC – DC Converter back View DC-DC Converter is provided to derive the necessary voltages to operate the UFSBI from the external 24V source provided. These internal power supplies are in hot standby mode.

The system operates with nominal 24V DC input supply. DC-DC Converter derives different supplies from the input. The specifications for the power supply are shown in the table below:

Input 4 24V DC +20% - 10%, 10 Amps

Output 1. 24V DC 4 Amps

2. 5V DC 4 Amps

3. +12V DC 1.5 Amps

4. –12V DC 1.5 Amps

The features of the power supply are: Input-output isolation. Input over voltage and under voltage protection. Output short circuit and over load protection. 24V DC output is isolated from other outputs. Ripple is less than 50mv at rated value. Efficiency is more than 70%. Works on “HOT STAND-BY” mode. PSMON(Power Supply Monitoring Unit) is provided to initiate audio visual

alarm in SM’s room on UFSBI ALARM PANEL discussed in a later chapter. Indication & Switches: The following Indication and switches are provided on DC-DC Converter Input 24V DC ON : The input 24V from Battery charger or UPS is coming to the I/P

of DC-DC converter through LPF and MCB Input 24V DC Reverse: The 24V input connection from Battery charger or is

connected to DC – DC converter with reverse polarity.

24V INPUT

24V OUTPUT

5V OUTPUT

+12V OUTPUT-12V OUTPUT

24V OUTPUT

5V OUTPUT

PSMONPSMON

5V +12V -12V 24V



UV Trip : The Input Voltage to DC-DC converter is below 19.2 volts. The system will not start.

OV Trip : The Input Voltage to DC-DC converter is above 30.2 volts. The system will not start.

IP ON : This indication is provided to check that 24V input for that specific card is present or not

OP ON : This indication is provided to check that output of that specific card is on or not.

SWITCH : For ON / OFF operation of DC-DC Converter which in turn Put On or Shut down the UFSBI DS

II. 2.2. UFSBI-DS consisting of the following parts i) Input card

ii) CPU card

iii) Control cum Communication Card (CCC)

iv) Output Card

v) Reset Box.

vi) MODEM.

vii) UFSBI Alarm Panel

The functionalities of each card is Given below

Input Card 1-6 CPU Card 1-3Output Card

1&2 CC Card

Reset Box

MODEM

Version Display



II.2.2. i) Input Card:- It is responsible for complementary sensing of the relay status of UFSBI. i.e. for sensing one pick up and one drop contact of each input relays. The sensing of relays is described in the figures below:

Relay Sensing by UFSBI:- These all relays are sensed by UFSBI through WAGO Board. Typical connection is given below The detailed interconnectivity diagram between WAGO Board to Mother Board is given below:

I/P RELAY 1- 8, O/P RELAY 1-8 & BIPR1 & BIPR2

INPUT CARD 1 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V



I/P RELAY 9 - 16, O/P RELAY 9 – 16




I/P RELAY, O/P RELAY & BIPR1 & BIPR2

INPUT CARD 1 & 2 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V



WAGO BOARD

MOTHER BOARD

WAGO TERMINAL

FRC TERMINAL

FRC CONNECTOR (Flat Cable)

FRC TERMINAL



`

WAGO TER. NO.

CIRCUIT CCT. SHEET REF

W1 REGULATED N24V FROM 24V OUTPUT OF DC-DC CONVERTER TO INPUT CARD. 6A OF 11 W2 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER TO INPUT CARD. 6A OF 11 W3 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TGTXR PICKUP

CONTACT TO INPUT CARD. 6A OF 11

W4 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH ASGNCR & CAN CO-OP R PICKUP CONTACT IN SERIES TO INPUT CARD.

6A OF 11

W5 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TCFR & BTSR PICKUP CONTACTS IN SERIES TO INPUT CARD.

6A OF 11

W6 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH ASGNCR PICKUP CONTACT TO INPUT CARD.

6A OF 11

W7 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH HSGNCR PICKUP CONTACT AND TCFR DROP CONTACT IN SERIES TO INPUT CARD.

6A OF 11

W8 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BPNR PICKUP CONTACT TO INPUT CARD.

6A OF 11

W9 OPEN 6A OF 11 W10 OPEN 6A OF 11 W11 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TGTXR DROP

CONTACT TO INPUT CARD. 6A OF 11

W12 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH ASGNCR & CAN CO-OP R DROP CONTACT IN PARALLEL TO INPUT CARD.

6A OF 11

WAGO BOARD TO MOTHERBOARD INTERCONNECTIVITY

1st Upper I/P Connector (I/P -1 to I/P 8 Complementary) On MB

1st Lower I/P Connector (O/P -1 to O/P 8, BIPR1 & BIPR2 Complementary)

1st Lower I/P Connector (O/P -1 to O/P 8, BIPR1 & BIPR2 Complementary) On WAGO Board

1st Upper I/P Connector (I/P -1 to I/P 8 Complementary) On WAGO Board

2nd Upper I/P Connector (I/P -9 to I/P 16 Complementary) On WAGO Board

2nd Lower I/P Connector (O/P -9 to O/P 16 Complementary) On WAGO Board

2nd Lower I/P Connector (O/P -9 to O/P 16 Complementary) On MB

2nd Upper I/P Connector (I/P -9 to I/P 16 Complementary) On MB O/P 1 to O/P 8

Relay Drive O/P 9 to O/P 16 Relay Drive

MB to MODEM Data Connector

MB 6 Pin Power Connector

BIPR1 & BIPR2 Relay Drive on MB

BIPR1 & BIPR2 Relay Drive on WAGO Board



WAGO TER. NO.


W13 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TCFR & BTSR,

DROP CONTACTS IN PARALLEL TO INPUT CARD. 6A OF 11

W14 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH ASGNCR DROP CONTACT TO INPUT CARD.

6A OF 11

W15 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH HSGNCR DROP CONTACT AND TCFR PICKUP CONTACT IN PARALLEL TO INPUT CARD.

6A OF 11

W16 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BPNR DROP CONTACT TO INPUT CARD.

6A OF 11

W17 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER TO INPUT CARD. 6A OF 11 W18 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH LFR PICKUP

CONTACT TO INPUT CARD. 6B OF 11

W19 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TCFXR PICKUP CONTACT TO INPUT CARD.

6B OF 11

W20 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TCFCR PICKUP CONTACT TO INPUT CARD.

6B OF 11

W21 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TGTYR PICKUP CONTACT TO INPUT CARD.

6B OF 11

W22 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH ASGNCPR PICKUP CONTACT TO INPUT CARD.

6B OF 11

W23 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TGTZR PICKUP CONTACT TO INPUT CARD.

6B OF 11

W24 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BLR PICKUP CONTACT TO INPUT CARD.

6B OF 11

W25 OPEN 6B OF 11 W26 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH LFR DROP

CONTACT TO INPUT CARD. 6B OF 11

W27 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TCFXR DROP CONTACT TO INPUT CARD.

6B OF 11

W28 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TCFCR DROP CONTACT TO INPUT CARD.

6B OF 11

W29 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TGTYR DROP CONTACT TO INPUT CARD.

6B OF 11

W30 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH ASGNCPR DROP CONTACT TO INPUT CARD.

6B OF 11

W31 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH TGTZR DROP CONTACT TO INPUT CARD.

6B OF 11

W32 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BLR DROP CONTACT TO INPUT CARD.

6B OF 11

W33 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER TO INPUT CARD. 6B OF 11 W34 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BIPR1 PICKUP

CONTACT TO INPUT CARD. 6C OF 11

W35 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BIPR2 PICKUP CONTACT TO INPUT CARD.

6C OF 11

W36 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BIPR1 DROP CONTACT TO INPUT CARD.

6C OF 11

W37 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER THROUGH BIPR2 DROP CONTACT .

6C OF 11

W38 OPEN W39 N24V FROM CC CARD TO BIPR1 R2 THROUGH RESET BOX 6C OF 11 W40 B24V FROM CC CARD TO BIPR1 R1 6C OF 11 W41 B24V FROM CC CARD TO BIPR2 R1 THROUGH RESET BOX 6C OF 11



WAGO TER. NO.


W42 N24V FROM CC CARD TO BIPR2 R2 6C OF 11 W43 NOT USED W44 B24V TO OUTPUT CARD THROUGH BIPR1 & BIPR2 PICK UP CONTACTS IN PARALLEL 6C OF 11 W45 NOT USED W46 NOT USED W47 B24V FROM OUTPUT CARD1 TO LFR R1 THROUGH TERMINAL NO. E68 (OUTPUT1) 6B OF 11 W48 N24V FROM OUTPUT CARD1 TO LFR R2 THROUGH TERMINAL NO. E68 (OUTPUT1) 6B OF 11 W49 B24V FROM OUTPUT CARD1 TO TCFXR R1 (OUTPUT2) 6B OF 11 W50 N24V FROM OUTPUT CARD1 TO TCFXR R2 (OUTPUT2) 6B OF 11 W51 B24V FROM OUTPUT CARD1 TO TCFCR R1 (OUTPUT3) 6B OF 11 W52 N24V FROM OUTPUT CARD1 TO TCFCR R2 (OUTPUT3) 6B OF 11 W53 B24V FROM OUTPUT CARD1 TO TGTYR R1 (OUTPUT4) 6B OF 11 W54 N24V FROM OUTPUT CARD1 TO TGTYR R2 (OUTPUT4) 6B OF 11 W55 B24V FROM OUTPUT CARD1 TO ASGNCPR R1 (OUTPUT5) 6B OF 11 W56 N24V FROM OUTPUT CARD1 TO ASGNCPR R2 (OUTPUT5) 6B OF 11 W57 B24V FROM OUTPUT CARD1 TO TGTZR R1 (OUTPUT6) 6B OF 11 W58 N24V FROM OUTPUT CARD1 TO TGTZR R2 (OUTPUT6) 6B OF 11 W59 N24V FROM OUTPUT CARD1 TO BLR R2 (OUTPUT7) 6B OF 11 W60 B24V FROM OUTPUT CARD1 TO BLR R1 (OUTPUT7) 6B OF 11 W61 OPEN(OUTPUT8) 6B OF 11 W62 OPEN(OUTPUT8) 6B OF 11 W63 REGULATED N24V FROM 24V OUTPUT OF DC-DC CONVERTER TO INPUT CARD. 6A OF 11

W64, W65, W66, W67, W68, W69, W70, W71 OPEN(CAN BE USE, TO CONNECT EXTRA INPUT FROM INPUT9 TO INPUT 16)

6A OF 11

W72, W73, W74, W75, W76, W77, W78,W79 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER TO INPUT CARD(CAN BE USE, TO CONNECT EXTRA INPUT FROM INPUT9 TO INPUT 16).

6A OF 11

W64, W65, W66, W67, W68, W69, W70, W71 OPEN(CAN BE USE, TO CONNECT EXTRA INPUT FROM INPUT9 TO INPUT 16)

6A OF 11

W80, W81,W82, W83,W84,W85,W86,W87 OPEN(CAN BE USE, TO CONNECT EXTRA OUTPUT FROM OUTPUT9 TO OUTPUT 16)

6B OF 11

W88, W89,W90,W91,W92,W93,W94,W95 REGULATED B24V FROM 24V OUTPUT OF DC-DC CONVERTER TO INPUT CARD (CAN BE USE, TO CONNECT EXTRA OUTPUT FROM OUTPUT9 TO OUTPUT 16).

6B OF 11

W96,W97,W98,W99,W100,W101 NOT IN USE W102& W103, W104 & W105, W106&W107,

W108 & W109, W110 & W111, W112 & W113, W114& W115, W116 & W117

OPEN (CAN BE USE, TO CONNECT EXTRA OUTPUT COILS FROM OUTPUT9 TO OUTPUT 16)

6B OF 11



II.2.2. ii) CPU Card:- The UFSBI system is works on a 2 out of 3 majority voting logic i.e. if one CPU card or its corresponding Input cards goes bad then also system can work. CPU – A read the Inputs through Input Card 1&2, CPU – B read the Inputs through Input Card 3&4 and CPU – C read the Inputs through Input Card 5&6. Thereafter validates the data by Inter-processor communication, adds CRC code and send this to CC card for transmission. On the other end after receiving the data from CC card it decodes it and sends that to Output card to pick up the Output relay. The Input reading process of CPU card working principle is shown in the figure below: II.2.2. iii) CCC Card:- The CCC Card mainly performs two important functions

a) It drives health check relays (BIPR1 & BIPR 2) and b) It converts the data provided by the CPU card as per RS 232 protocol and

sends it to the Modem. The process of functioning of CCC Card is shown in the figure below:

INPUT CARD 1&2 a. Opt isolation of Relay Inputs. b. Conversion of 24V to 5 V

I/P RELAY O/P RELAY & BIPR1 & BIPR2



CPU CARD A a. Input debouncing b. Input Data validation after interprocessor communication c. adding CRC code

CPU CARD B a. Input debouncing b. Input Data validation after interprocessor communication c. adding CRC code

CPU CARD C a. Input debouncing b. Input Data validation after interprocessor communication c. adding CRC code

Input Card 1 & 2 1. Opto Isolation of Relay Inputs2. Noise & Surge suppressor



CPU A1. Input De-bouncing2. Input data validation by Inter

Processor communication 3. Adding CRC codes

CPU B 1. Input De-bouncing2. Input data validation by Inter Processor communication3. Adding CRC codes

CPU C1. Input De-bouncing

2. Input data validation by Inter Processor communication 3. Adding CRC codes

PICK UP

DROP OUT

TO MODEM

Control & Communication Card

1. Data received from 3 CPUs on Time Division

basis 2. TTL to RS232 level conversion

Complementarysensing of an

Input Relay State



II.2.2.iv) Output Card:- 2 numbers of such cards are provided for driving Output relay. 1st Output card drives Output relay 1 to 8 and rest 9 - 16 number output relay is driven by Output card 2. II.2.2. v) MODEM :- Modem is provided to convert the data as per RS232 to Voice Frequency. The following Fig shows the front and back view of the Modem. Modem works on 4 wire, Asynchronous, 2400 bps mode. Maximum permitted loss between to modem is 30db.

FROM MODEM

OUTPUTRELAY

Output Card 1. Hardware 2/3 Voter Unit 2. Output through DC to DC converter

3. Decesion Read back by each CPU

CPU A 1. Received data validation

by Processor 2. Performing 2 out of 3

Software Voting

Control & Communication Card

1. RS232 toTTL level conversion2. Data sent to 3 CPUs

CPU B 1. Received data validation by Processor

2. Performing 2 out of 3 Software Voting

CPU C 1. Received data validation by Processor 2. Performing 2 out of 3

Software Voting

MODEM FRONT VIEW MODEM BACK VIEW

Loop / Normal Switch To Test the Modem

Data Connector from Mother Board to Modem

MODEM ON/OFF Switch

ANS/ORG Switch To select the mode

PWR IN

Line Connector from MODEM to OFC or QUAD Cable

Steady Red. To Indicate the MODEM Power ON Condition

Steady Red to Indicate The Carrier Detect

Flashing Red. To Indicate the MODEM receives Data

Flashing Red. To Indicate the MODEM Sends Data

Flashing Red during initial handshaking.



MODEM

GREEN

BLACK

TO DC-DC CONVERTER +12V

TO DC-DC CONVERTER +12V COMMON

TO DC-DC CONVERTER -12V

MODEM POWER CONNECTION

YELLOW

MO D EM -1

SURGE ARRESTER MODULE

OFC MUX

VOICE CHANNEL

RX (YELLOW)

RX (BLACK)

OFC MUX

VOICE CHANNEL

SURGE ARRESTER MODULE TX (GREEN)

TX (RED)

MO D EM -2

TX (GREEN)

TX (RED)

RX (YELLOW)

RX (BLACK)

MODEM TO MODEM INTERCONNECTION BETWEEN TWO UFSBI ON VOICE CHANNEL OF OFC

STATION –“A” STATION –“B”

GREEN / ORANGE 1

2

3

4

5

6

7

8

9

MODEM 9-PIN LINE CONNECTOR(F)

TWO WAY TERMINAL

RED / ORANGE WITH WHITE DOT

YELLOW / BLUE

BLACK / BLUE WITH WHITE DOT

TX

RX

MODEM TO LINE CONNECTION

MODEM TO MOTHERBOARD DATA CONNECTION

MB 9-PIN DATA CONNECTOR(M)

MODEM 9-PIN DATA CONNECTOR(M)

RX (GREEN / BLUE)

GND (BLACK / BLUE WITH WHITE DOT ) TX (RED / ORANGE))

(GREEN)

(RED/GREEN WITH WHITE DOT))

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

To Reset Box for Link Fail Ind.

To Reset Box for Single CPU Fail Ind.



II.2.2.vi) Reset Box:-

The functions of all the components are given below: 1. Counter: It keeps track of the number of Reset operations taking place. The counter is non-resettable electro-magnetic type. 2. RESET Button: Sometimes the power-off and power-on sequence may not lead to display "0b” (ready to press BI- ON button) on all CPUs. In that case press the RESET button so that the CPUs again resets itself to show “0b”(ready to press BI-ON button) on all CPUs.

3. BI-ON Button: This button is required for starting the system. Whenever all the CPUs display “0b”, it indicates that it is ready for start. The user has to press this button for starting the system.

4. BZ-ACK Button: This button is required for acknowledging the buzzer whenever it sounds due to dropping of “Shut down relays” (BIPR1 & BIPR2).

RESET BOX FRONT VIEW RESET BOX BACK VIEW

MO

DE

M -

ISURGE

ARRESTORMODULE

(SAM)

Rx

Rx

Tx

Tx

YELLOW

BLACK

RED

GREEN

Rx

Rx

Tx

Tx

YELLOW

BLACK

RED

GREEN

Rx

Rx

Tx

Tx

'A' Wire

'B' Wire

'C' Wire

'D' Wire

MO

DE

M -

IISURGEARRESTOR

MODULE(SAM)

Tx

Tx

Rx

Rx

GREEN

RED

BLACK

YELLOW

Tx

Tx

Rx

Rx

GREEN

RED

BLACK

YELLOW

Tx

Tx

Rx

Rx

STATION A STATION B

QU

AD

CA

BLE

( IR

S: T

C 3

0-05

)

VF TRANSFORMER(600:470)

'A' Wire

'B' Wire

'C' Wire

'D' Wire

VF TRANSFORMER(470:600)

CONNECTIVITY BETWEEN TWO MODEMS THROUGH COPPER CONDUCTOR OF QUAD CABLE



5. BI-OK IND.: This indication (green) glows when the UFSBI is in working condition.

6. BI-FAIL IND.: This indication (red) glows when the Block Interface is in failure mode. 7. LINK FAIL IND.: This indication (yellow) glows steadily when the modem fails to receive any data from remote station. In normal working condition, when the modem receives data from remote station, this indication (yellow) will flicker continuously. Flickering of this indication does not necessarily means that the UFSBI communication is fully established. Full establishment of UFSBI communication is only decided by seeing “00” in the CPU cards and O/P relays are picking up. POWER-ON-RESET Operation The following steps are to be performed for carrying out the RESET operation of the UFSBI:

Turn off the system power. Wait for 1 minute. Power-on the system. Check the display of the CPU. Wait till the display on all the CPUs display “0b” If “0b” is not displayed, try by pressing the RESET button. If the problem

persists check corresponding codes in the error code list and take appropriate action as suggested in the remedial action column.

If all the CPUs display “0b” then press the BI-ON button. Observe that both BIPR1 and BIPR2 pick up immediately after BI-ON is

pressed. Once BIPR1 and BIPR2 pick up, BI fail (Red) indication goes off and BI OK

(Green) indication comes on. Link fail (Yellow) steady indication goes off & starts flickering as soon as the

modem starts communicating with remote station modem and all the CPU’s display “00”

RESET Operation The following steps are to be performed for carrying out the RESET operation of the UFSBI:

Press the Reset Button and see that the display in all 3 CPU’s becomes “--“ Wait till the display on all the CPUs display “0b” If “0b” is not displayed, try by pressing the RESET button. If the problem

persists check corresponding codes in the error code list and take appropriate action as suggested in the remedial action column.

If all the CPUs display “0b” then press the BI-ON button. Observe that both BIPR1 and BIPR2 pick up immediately after BI-ON is

pressed.



Once BIPR1 and BIPR2 pick up, BI fail (Red) indication goes off and BI OK (Green) indication comes on.

Link fail (Yellow) steady indication goes off & starts flickering as soon as the modem starts communicating with remote station modem and all the CPU’s display “00”

II.2.2.vii) UFSBI Alarm Panel :- The UFSBI alarm panel provided at SM room to give preventive alarm for single CPU failure, Redundant DC-DC converter failure and System total failure.

The UFSBI alarm panel box consists of following components is given below: 1. ACKN. Button for Single CPU fail: To mute the buzzer if any one of the CPU of UFSBI goes bad. 2. ACKN. Button for redundant DC-DC Converter: To mute the buzzer if any module of DC-DC converter goes bad. 3. ACKN. Button for system failure: To mute the buzzer if UFSBI system goes to shut down mode.

4. Indication (R) for Single CPU fail: It glows when any one of the CPU of UFSBI goes bad and remains “ON” till the fault rectified. 5. Indication (R) for Redundant DC-DC: It glows when any module of DC-DC converter goes bad and remains “ON” till the fault rectified. 6. Indication (R) for system failure: It glows when UFSBI system goes to shut down mode and remains “ON” till the fault rectified. Note: - The System failure indication (audio & visual) would be “ON” till the UFSBI functioning normally (BIPR1 and BIPR2 picks up).

Connectivity between UFSBI Alarm panel to BPAC & Datalogger.

Sl. no.

UFSBI Alarm panel terminal

no.

BPAC terminal No.

Potential Free Contact for Data

Logger

Remarks

1. 1 141 142 For Power Supply Monitor 2. 2 137 143

3. 3 144 145 For Single CPU Failure (SCFD) 4. 4 137 146

5. 5 147 138 For System Failure 6. 6 137 139

UFSBI ALARM PANEL FRONT VIEW UFSBI ALARM PANEL BACK VIEW

Size of the alarm panel : Size of the ALARM PANEL : L 10” X W 6” X H 4”



136

E136

E139

139

E138

138

UFS

BI

ALA

RM

PA

NEL

W

IRIN

G D

IAG

RA

M

140

E140

E146

146

E145

145

E137

137

E147

147

E144

144

E143

143E1

4214

2

E141

141

INSID

E U

FSBI

CU

BIC

LE P

LAC

ED A

T REL

AY

RO

OM

HO

USED

IN

A B

OX A

ND

PLA

CED

AT

SM

/ASM

RO

OM



II.2.2.viii) UFSBI Address Configuration Jumpers The Address Configuration jumpers are set in the Connector side of the motherboard. A pattern of this jumper setting is shown below:

Left Center Right Left Center Right

TX TX 1 2 3 4 5 6 7 8 RX RX 9 10 11 12 13 14 15 16

The TX Address of one unit should correspond with the RX Address of other unit. The same type of settings should not be used in the adjacent pair of units.

NOTE: 9 unique Address Configuration Jumpers are given in Annexure A.

II.3. UFSBI installation guide The following practices is to be observed in installing UFSBI at site: a) Battery: As per Item No. I.5 of this manual. b) Battery Charger: As per Clause No. I.6 of this manual c) Earthing: Good earthing is to be provided preferably less than 1 a) Communication Channel:

Allowable Channel Loss: 30 dB (max.) between 2 modems SNR: 20 dB (minimum)

GD1

IN1

IN2

IN3

IN4

EARTH

OUT4

OUT3

OUT2

EARTH

OUT1

R1

R3 R5

R7

R8

R6R4

R2

C1 C2

C3 C4

C5

C6

C7

C8 C12

C11

C10C9

C16C15

C14C13

M1

M2 M4 M6 M8

M7M5M3

GD1 GD2

GD2 GD3

GD3 GD4

GD4

Fig: Circuit for Surge Arrestor Module (SAM)



Transmit Power: -5 to -7dBm (maximum at modem Tx pin) Receive Level: -35 dBm (minimum at modem Rx pin)

The channel should be of good quality and must have steady performance for at least 72 hours before commissioning

NOTE: A list of commissioning pre-requisites in the form of a check sheet is provided in Annexure B.

II.4. Installation Procedures Installation & Testing Guidelines

All the units including the modules, connectors and other accessories are factory-checked. However, after unpacking, following pre-installation test schedule is being recommended to examine if any kind of damage has occurred during transshipment.

Physical Examination required for a) Connectors b) Relays and Relay-bases c) All the PCB modules d) Rack and the mainframe e) Card Guides f) Motherboard g) Interconnecting ribbon cables and wires h) Reset Box i) Modem NOTE: Pre-commissioning observation must be carried out as per Annexure B and Annexure D and the data should be recorded as directed. If any major damage is found it is to be brought to the notice of site supervisor.

Power Supply a) Battery Voltage should not exceed the range: 19.5V to 28.8V DC. b) Ensure that the above supply is not arbitrarily grounded. c) Before insertion of other modules, DC-DC converter is to be connected to

the Battery Supply and its correct output levels should read as: i) 5V [+/- 3%) ii) +12V [+/- 2%] iii) –12V [+/- 2%] iv) 24V [+/- 5%]

Starting the UFSBI Installation of system is kept very simple; as such no elaborate procedure is required except those given as under:

a) Plug in all the relays to the respective relay bases as per Relay disposition chart.

b) Insert all the PCB’s in the 6U Rack. c) Plug in all the connectors to their matched counter part. As the length or

wire groups corresponding to each counter part is optimally fixed, probability of wrong connection is ruled out. Refer interconnection drawings (Pg 35/62) for proper connections.



WARNING: For removing and fitting PCB in the unit, please switch off the power supply.

Now switch ‘ON’ the power supply of the unit and check for: a) All the indications in DC-DC converter. b) Red indication in Reset Box and Buzzer sounds. c) Press the RESET switch and wait for 5 seconds. d) Press the BIPR ON switch. BIPR1 and BIPR2 relays will pick up. e) Buzzer stops and red indication in reset box changes to green. f) All CPU’s will display “00” indicating UFSBI is normal. g) Connect an auto simulator. h) Now UFSBI starts functioning in loop.

Railways are to provide the following facilities for installation and commissioning of block panel with UFSBI

Battery Charger Battery Terminal Block for field connections. Earthing: A good earthing for termination of the equipment A 4 wire full duplex OFC Voice Channel or Quad cable

(Refer to the Pre-Installation Check list in Annexure B for details of the above) A “TEST SIGNALLING ROUND” involving at least 10 operations needs to be

performed before the real operations or the trial run starts. The block operation through Block Proving With Axle Counter using UFSBIis to be kept under observation at least for three up and three down movements of trains.

A close monitoring of the train movements through Block Proving With Axle Counter using UFSBIto be done at least for 48 Hrs after immediate installation and commissioning of the system.

II.5. Maintenance Preventive maintenance

Power supply: In tropical countries power supply unit of any type is the single source responsible for most of the equipment faults and malfunctioning. A regular check on power supply units such as battery banks, battery charger and DC-DC converters is mandatory.

Relays: UFSBI has used most reliable type of relays, but special care and testing is required for those to be used after long storage. No attempt is to be made to repair a relay. Use a new one.

DO’s and DON’T’s given at page 41/62 can be a formidable guideline for Preventive Maintenance.

Maintenance of Communication Link

Telecom cable is to be protected from injury during other kinds of installation at its vicinity.



If disconnection of cable is required, the cable terminal is to be refitted firmly.

The loss of signal due to lossy cable is to be kept under check. The display indication “33” indicates link failure. If the modem is found to be

O.K, next to be checked is the telecom cable.

Maintenance of Equipment

a. UFSBI unit will automatically trip-off if the Battery supply goes below 19.2V & above 28.8V DC. In case of repeated trip-off, both the DC supply level and the loading are to be checked. A healthy UFSBI should not draw more than 1.8 Amp DC.

b. No attempt of “resetting” is to be made in case of supply impairment or link failure.

c. If a faulty UFSBI system is not brought back to normal after “resetting” one must check: i) If there is any loosely fitted connector or improperly pressed PCB module. ii) Connecting leads inserted in Terminal. iii) The DC supply levels of the DC-DC converter.

d. For specific information on faults, refer “UFSBI Error Code List”. e. Once a fault is found, the user should not attempt repairing at component

level. The impaired module / PCB needs to be replaced by a spare one. II.6. Do’s & Don’ts

UFSBI system is to be operated or maintained only by trained persons No attempt is to be made to operate the equipment at Battery Voltage

ranging bellow 19.2V and above 28.8V DC. Connectors or PCBs is to be plugged in or out after switching off the Power

Supply. “RESET” should not be applied in case of “Link Failure” or “Supply” Break

Down. Replacement of components or modules is to be done with spares supplied

/ prescribed by the manufacturer. While plugging in / out a PCB, care is to be taken to avoid application of

excessive force. Arbitrary grounding should not be done to any “common” terminal inside

the equipment. Relay testing should not be performed involving forced ‘pick-up’ or ‘drop’

while the instrument is “ON”. Standard restrictions against mishandling and opening of Block Instrument

are applicable also to UFSBI. WARNING: No violation of above “MESSAGE OF CAUTION” is desirable for safe &

reliable signalling operation.



II.7 Error code list & recommended actions

GENERAL INSTRUCTION In case of any fault, please follow the steps in the order as stated below:

1. Note the codes shown on the CPU and the LED on the Output cards and the Control & Communication card.

2. It should also be recorded that under which condition the failure occurs, i.e. whether it occurs repeatedly during a certain operation or is it flitting in nature.

3. Perform a Power-On-Reset following the steps given in the item II.15 of Block Panel with UFSBI, Users Manual.

4. In case the problem persists or recurs even after Power-On-Reset then follow the “Fault finding Procedure” as stated in Annexure C

5. During troubleshooting, whenever directed to check the effect of any change or replacement of card, please perform Power-On-Reset as stated in the item II.15 and observe the system for sometime. NOTE: REFER ANNEXURE C FOR DETAILED ERROR CODE LIST ALONG WITH RECOMMENDED

REMEDIAL ACTIONS



ANNEXTURE - B

Pre- Commissioning Check List Of BPAC Using Universal Fail Safe Block Interface (UFSBI) and SSDAC for Double Line

Name and Type of Equipment:

BPAC using Universal Fail Safe Block Interface (UFSBI) and SSDAC

Specification No: IRS:S-105/2012

Name and Address of manufacturer/supplier:

M/s Deltron Equipment & Systems Pvt.Ltd. 26, Convent Road, Kolkata-700 014

Serial number of the equipment:

Station Name:

Division/Zonal Railway:

Software checksum: ‘B7 0E’

UFSBI working on: OFC / Microwave / Quad Cable

DATE OF INSTALLATION:

DATE OF COMMISSIONING:

DATE OF INSPECTION:

Note:

1. System should be installed and commissioned by authorized technical staff of manufacturer only.

2. Commissioning of Universal Fail Safe Block Interface (UFSBI) 4 has to be done by OEM as per RDSO approved pre-commissioning checklist No. SIG 0611 Ver.0.

3. OEM shall certify that verification of system installation has been completed by OEM and all necessary arrangements meet the required standards of engineering for trouble free working of installed system. (Ref: This office letter no.: STS.E.AC.Dig.Genl dt 21.06.2011)



Sl. No.

Description Specified Value / nos.

Obtained Value / Nos.

(if any)

Ok / Not Ok

1. Environment Spacious, Clean, Dry, Well ventilated room preferably with a fan/ exhaust fan. Space for SM’s panel at SM room – 610 x 400 x 465 Cubic mm. Space for UFSBI alarm panel at SM’s room - 265 x 170 x 105 Cubic mm Space for UFSBI cubicle at Relay room - 1430 x 710 x 480 Cubic mm

2. Battery 2 x 12 V / 120 AH

3. Battery Charger Good Quality low ripple battery charger (Axle Counter type) as per IRS: S-86/2000 or IPS module as per RDSO/SPN/165/2004 Nominal Voltage – 24 V/10A (-10% to +20%) at The Output voltage at following 2 conditions must be within 21.6V to 28.8V:

Charger ON & UFSBI ON Charger OFF (for 15 min) & UFSBI ON

(Note: The output voltage must be measured at the terminals DC-DC Converter Input)

________ V ________ V

4. Earthing

Separate earthing should be provided for UFSBI cubicle. Value of Earth resistance: < 1 ohms

5. Lightning Arrestor Good lightning protection system with proper connection with earth provided from any of the following firms:- M/s Phoenix Contacts or M/s Cape Electric Corpn. or M/s MCML Systems Pvt. Ltd. or M/s Adhunik Power Systems or OBO Bettermann India (P) Ltd. Or CITEL or ERICO.

6. Communication Channel

4 wire Voice Channel on OFC (2400 bps , asynchronous)

Max. Tx Signal: -7 dBm to -5 dBm Min. Rx. Level: -12 dBm to -14dBm

- ________ dBm ________ dBm



Sl. No.

Description Specified Value / nos.

Obtained Value / Nos.

(if any)

Ok / Not Ok

7.

Communication Cable

Jelly filled Quad Cable as per specn: IRS: TC 30-05

Length of quad cable: The cable insulation (must be better

than10 M when tested with 500V Megger):

Loop resistance (should be less than 55 /Km):

Signal loss (should be less than 30 dB at 2.5 KHz):

Near End Cross talk (should be better than 55dB/Km at a frequency of 150 KHz):

Far End Cross talk (should be better than 67.8 dB/Km at a frequency of 150 KHz) :

The armor of the cable must be properly earthed.

The cable shall be terminated as stated in Annexure A

________ Km ________ M ________ ________ dB ________ dB ________ dB

8.

External Terminals (Centre Link Open type )

All inputs from the Field, Block Instruments and the Relay room shall be terminated with proper identification in a separate location to connect to the UFSBI terminals

9. 1 x 60C indoor /Outdoor of 0.9 Sq.mm diameter cable

For interconnection between SM-Panel to BPAC cubicle. Length is as per distance between SM panel at SM room to BPAC cubicle. Out of 60 core 48 cores are used and rest are spare.

10. 1 x 40C indoor cable of 0.9 Sq.mm diameter cable

For interconnection between relay rack to BPAC cubicle. Length is as per distance between CTR at relay room to BPAC cubicle.

11 Copper Wire of 2.5 Sq.mm dia (Red & Black in colour)

For provision of power supply for BPAC. Length is as per distance between battery charger or IPS room to BPAC to cubicle.

12. V/F tapping transformer

For the system which has to run on copper cable in RE area V/F tapping transformer is required as per IRS:TC 76-2000 Characteristics impedance of the V/F transformer is 600 on primary side (i.e. BPAC MODEM side) and Quad cable impedance on secondary side (normally 470).

13. Relays For One Block section number of relays are given below For Double Line: QN1(8F/8B) – 38, QNA1(8F/8B) – 14, QL1 (11F/4B) – 4, Electronic fail safe Timer - 2



Signal checking: Check the Block Instruments Indication for the Following condition:

Sl. No.

Test Observed result (OK / NOT OK)

STATION “A” STATION “B” 01. SM’s Key Control on Line Clear

02. Refusal of Line Clear enquiry through LCB Key Control

03. Normal Train Movement ( For at least 2 trains from both direction)

04. Cancellation of Line Clear (From Both side) and check Cancel Counter

05. Advance Starter should not go to Green (taken OFF) without Line Clear

06. Advance Starter should not go to Green (taken OFF) if UFSBI fails after taking of Line Clear

07. Advance Starter should not go to Green (taken OFF) after Train enters block section

08. Advance Starter should not go to Green (taken OFF) after Train clears the block section but the Block instrument does not go to Line Closed condition due to any reason. The advance starter should come only after Block Instrument goes to First Line Closed then a fresh Line Clear is taken. (One train One Slot condition)

09. Advance Starter should not Fly Back from Green to Red (OFF - ON) due to UFSBI System failure or UFSBI Link failure.

10. Cancel CO-OP cannot be extended from train sending station unless and until Advance starter signal and it’s all controls are normal.



Unit details. (A) Input Cards. : 6 nos. 1. Sl. no. : Deltron/UFSBI/Input ………………. 2. Sl. no. : Deltron/UFSBI/Input ………………. 3. Sl. no. : Deltron/UFSBI/Input ………………. 4. Sl. no. : Deltron/UFSBI/Input ………………. 5. Sl. no. : Deltron/UFSBI/Input ………………. 6. Sl. no. : Deltron/UFSBI/Input ………………. (B) CPU Cards. : 3 nos. 1. Sl. no. : Deltron/UFSBI/CPU ………………. 2. Sl. no. : Deltron/UFSBI/CPU ………………. 3. Sl. no. : Deltron/UFSBI/CPU ………………. (C) Output Cards. : 2 nos. 1. Sl. no. : Deltron/UFSBI/ Output………………. 2. Sl. no. : Deltron/UFSBI/ Output………………. (D) Com. & Con. Card. : 1 no. 1. Sl. no. : Deltron/UFSBI/ CCC………………. (E) Reset Box. : 1 no. 1. Sl. no. : Deltron/UFSBI/ RSTBX………………. (F) Modem. : 1 no.

1. Sl. no. : Deltron/UFSBI/ Modem/P………………. Settings : LOOP ANS

1 2

NORMAL ORG



(G) Relays. : To be supplied by Railways as per system Requirement. (H) Power supply. : 1 no (with hot standby) 1. Sl. no. : …………………………… (I) Personality module. : 1 set. 1. PSM card. : 1 no. Sl no. : Deltron/UFSBI/PSM………………. 2. IFU TX : 1 no. Sl no. : ………………………………… 3. IFU RX : 1 no.. Sl no. : ………………………………… 4. IFU Driver : 1 no. Sl no. : ………………………………… (J) Initial Reset Count. : Commissioning Reset Count. : (K) Address Pairs. TX RX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



ANNEXURE - C Error code list & Recommended actions for Block Working With UFSBI & DAC in case of Faults/Errors

NOTE: BEFORE TAKING OUT OR INSERTING A CARD, ALWAYS TURN-OFF THE POWER SUPPLY

Codes Failure Cause Recommended Actions

00 NORMAL MODE.

a) Flashing ‘00’ indicates that the system is healthy & functioning properly. b) If this code becomes steady in certain CPU and an error code of ‘37’, ‘38’ or ‘39’ appears (according to the stuck CPU) on the other CPU’s try “RESETTING” the system as stated in item no. II.16. c) In case the problem persists change the CPU showing the steady code.

01 Output Latch 1 Read-back bad a) If the code is displayed simultaneously in more than 1 CPU: Then check if the CCC card is inserted properly in the slot. If the problem still persists replace the CCC card. b) If the code comes on a single CPU:

i) First swap the faulty CPU with another slot. ii) If the code shifts with the CPU to the new slot,

change the CPU card else change the Output card

02 Output Latch 2 Read-back bad

05 UFSBI source address mismatch in receive message

Check Address jumpers of both mother cards of connected UFSBI units for their correspondence refer page 33. If the fault is in one CPU card only (unlikely) replace the CPU card.

06 UFSBI destination address mismatch in receive message

Check Address jumpers of both mother cards of connected UFSBI units for their correspondence refer page 33. If the fault is in one CPU card only (unlikely) replace the CPU card.

07

TXENABLE-A/B/C signal produced by Inter-block data selector logic in CCC not matching with Inter-block

phase.

If this occurs in all the CPUs, change the CCC Card. This can also happen when the UFSBI is working in 2/2 mode and a further failure occurs. This is not a serious problem and will go up on “RESET”.

08 CPU failed to transmit a) Swap the CPU with another slot, if the problem shifts with the CPU , then change the CPU card. b) Check the system, if the fault persists in the same slot, change the CCC card.

0A Clear input to U9 low

0B(Ob)

Ready to accept 'start' command after POST

a) Press “BI-ON” button to start the system within 30 sec. If the button is not pressed in time then all the three CPUs will display “99” code and go to shut down. To recover from this problem the power supply is to be turned off and the on. After the POST process all the CPUs will display “Ob” again.

b) In case anyone CPU is showing steady 0B, while others are running with 37, 38 or 39, try “RESETTING” the system.

0C PS monitor test in progress in POST Wait for all CPUs to display “Ob”.

10 IN1 complementary failure (Ckt ref. W2 & W10) Manually RESET the system. If the problem persists then

i) In case the Error Code is appearing in 1 of the 3 CPU’s,

a) Swap the Input Card 1 with another Input Card 1 for Error Codes “10” to “1F”, observe the outcome

b) Swap the Input Card 2 with another Input Card 2 for Error Codes “20” to “2F”, observe the outcome.

11 IN2 complementary failure (Ckt ref. W3 & W11)






In case (I)-a,b fails to solve the problem, c) Change Input Card 1 for Error Codes “10” to “1F” d) Change Input Card 2 for Error Codes “20” to “2F”

Manually RESET the system and observe its operation

ii) If the Error codes are appearing in at least 2 of the 3 CPU’s simultaneously then check voltages at the respective relay contacts and wago terminals as per circuit diagram Sh. 6A and 6B of 12 of RDSO/S/32018 (attached in the Manual) for the inputs IN1-IN7 (Wago W2-W8) and inputs IN1’-IN7’ (Wago W10-W15). For other inputs like IN8, IN9-IN16 (Wago W9, W64-W71) and IN8’, IN9’-IN16’ (Wago W17, W72-W79) check the looping as per circuit referred above. Manually RESET the system and observe its operation

iii) If the problem still persists check the flat cable connections between the wago board and motherboard as per dig. 2.1. Manually RESET the system and observe its operation

iv) In case the error still persists, replace- a) Input Card 1 for Error Codes “10” to “1F” b) Input Card 2 for Error Codes “20” to “2F”





18 OUT1 complementary failure (Ckt ref. W18 & W26)


1A OUT3 complementary failure (Ckt ref. W20 & W28)

1B OUT4 complementary failure (Ckt ref. W21 & W29)

1C OUT5 complementary failure (Ckt ref. W22 & W30)

1D OUT6 complementary failure (Ckt ref. W23 & W31)

1E OUT7 complementary failure (Ckt ref. W24 & W32)

'1 ' (1F) OUT8 complementary failure (Ckt ref. W25 & W33)


Manually RESET the system following the same process as stated in item no. ****. If the problem persists then

In case the Error Code is appearing in 1 of the 3 CPU’s, a) Swap the Input Card 1 with another Input Card 1 for

Error Codes “10” to “1F”, observe the outcome b) Swap the Input Card 2 with another Input Card 2 for

Error Codes “20” to “2F”, observe the outcome. In case (I)-a,b fails to solve the problem, c) Change Input Card 1 for Error Codes “10” to “1F” d) Change Input Card 2 for Error Codes “20” to “2F”


If the Error codes are appearing in at least 2 of the 3 CPU’s simultaneously then check voltages at the respective relay contacts and wago terminals as per circuit diagram Sh. 6A and 6B of 12 of RDSO/S/32018 (attached in the Manual) for the inputs. Manually RESET the system and observe its operation

i) If the problem still persists check the flat cable connections between the wago board and motherboard as per dig. 2.1. Manually RESET the system and observe its operation

ii) In case the error still persists, replace- a) Input Card 1 for Error Codes “10” to “1F” b) Input Card 2 for Error Codes “20” to “2F”











2A OUT11 complementary failure (Ckt ref. W82 & W90)

2B OUT12 complementary failure (Ckt ref. W83 & W91)

2C OUT13 complementary failure (Ckt ref. W84 & W92)

2D OUT14 complementary failure (Ckt ref. W85 & W93)

2E OUT15 complementary failure (Ckt ref. W86 & W94)

'2 ' (2F) OUT16 complementary failure (Ckt ref. W87 & W95)

30 BIPR1 complementary failure Take similar steps as in the case for other relays.

31 BIPR2complementary failure 33 Link Fail (SSB mode) If the error code appears in any one of the CPU card:



i) Swap it with other slot. If the error shifts with the card Change the CPU card. If the error code appears in any one of the CPU card: i) Check the communication link from crone box, terminal, to

modem RJ11 jack. If external communication link is confirmed OK change the CCC Card.

ii) If the problem still persists, Switch off the Modem, and then restart it after 60s.

iii) If the problem still persists perform Power-On Reset of the System and observe its operation

34 RSSB mode

This mode indicates that the UFSBI on the other side is not receiving data. Try by checking the channel, modem and communication in that order as stated for error code ‘33’. Ensure that the other side System is working and showing error code ‘33’ only.

37 CPU A bad i) Change corresponding CPU Cards in which the static error code is showing. Manually RESET the system and observe its operation. ii) If this indication is on all the CPU cards then change the CCC (Communication) Card. Manually RESET the system and observe its operation

38 CPU B bad 39 CPU C bad

3A Inter-processor communication channel failure (common mode)

If occurs in all the CPUs, change the communication card. Manually RESET the system and observe its operation

40 OUT1 forced pickup [LFR Non-vital relay]

Manually RESET the system following the same process as stated in item no. II.15. If the problem persists then For codes “40” to “4F” check the corresponding relays as follows i) Check if the relay is properly plugged and the

retaining clip is place correctly. Also ensure that all its receptacles are rightly placed and locked in the plug board. Manually RESET the system and observe its operation.

ii) Check the corresponding relays to see if the front contacts somehow got voltage or back contacts got broken or if the relay has got picked up out of sequence by some stray feed given externally. Manually RESET the system and observe its operation.

iii) Check the wago terminals for unwanted shorting between terminals other than those showed in circuit. In case any such short circuits found please remove the same. Manually RESET the system and observe its operation.

41 OUT2 forced pickup [TCFXR vital relay]

42 OUT3 forced pickup [TCFCR vital relay]

43 OUT4 forced pickup [TGTYR vital relay]

44 OUT5 forced pickup [ASGNCPR vital relay]

45 OUT6 forced pickup [TGTZR vital relay]

46 OUT7 forced pickup [BLR vital relay]

47 OUT8 forced pickup

48 OUT9 forced pickup Manually RESET the system following the same process as stated in item no. II.15. If the problem persists then For codes “40” to “4F” check the corresponding relays as follows iv) Check if the relay is properly plugged and the

retaining clip is place correctly. Also ensure that all its receptacles are rightly placed and locked in the plug board. Manually RESET the system and observe its operation.

v) Check the corresponding relays to see if the front contacts somehow got voltage or back contacts got broken or if the relay has got picked up out of sequence by some stray feed given externally. Manually RESET the system and observe its

49 OUT10 forced pickup

4A OUT11 forced pickup

4B OUT12 forced pickup

4C OUT13 forced pickup

4D OUT14 forced pickup

4E OUT15 forced pickup



4F OUT16 forced pickup operation. vi) Check the wago terminals for unwanted shorting

between terminals other than those showed in circuit. In case any such short circuits found please remove the same. Manually RESET the system and observe its operation.

50 IN1 jitter Jittery contacts of the relay may occur when a particular relay does not stabilize, i.e. it ‘chatters’. This may happen due to low coil voltage, faulty receptacles (coil or contacts) or improper plugging of the relays without retaining clips. The following actions are suggested: a) Check the setting in the plug board for proper plugging b) Check firmness of the contacts and all connections from

output connector coil (for output relays). c) Check coil and contact voltage for each input paths

from the circuit. Try removing and re-plugging each relay in the circuit path separately ensuring that it is fitted firmly to the plug board and the retaining clip is in the right place

d) For output relays, try to measure the coil voltage at the corresponding wago terminal as well as the relay coil R1-R2. Note that this voltage is available for less than ½ sec, so using an analog voltmeter is preferred. It is advisable to try by changing the corresponding output card.

Manually RESET the system and observe its operation.

51 IN2 jitter 52 IN3 jitter 53 IN4 jitter 54 IN5 jitter 55 IN6 jitter 56 IN7 jitter 57 IN8 jitter 58 OUT1 jitter [LFR Non-vital relay] 59 OUT2 jitter [TCFXR vital relay] 5A OUT3 jitter [TCFCR vital relay] 5B OUT4 jitter [TGTYR vital relay] 5C OUT5 jitter [ASGNCPR vital relay] 5D OUT6 jitter [TGTZR vital relay] 5E OUT7 jitter [BLR vital relay] 5F OUT8 jitter 60 IN9 jitter 61 IN10 jitter Jittery contacts of the relay may occur when a particular

relay does not stabilize, i.e. it ‘chatters’. This may happen due to low coil voltage, faulty receptacles (coil or contacts) or improper plugging of the relays without retaining clips. The following actions are suggested: a) Check the setting in the plug board for proper plugging b) Check firmness of the contacts and all connections from

output connector coil (for output relays). c) Check coil and contact voltage for each input paths

from the circuit. Try removing and re-plugging each relay in the circuit path separately ensuring that it is fitted firmly to the plug board and the retaining clip is in the right place

d) For output relays, try to measure the coil voltage at the corresponding wago terminal as well as the relay coil R1-R2. Note that this voltage is available for less than ½ sec, so using an analog voltmeter is preferred. It is advisable to try by changing the corresponding output card.

Manually RESET the system and observe its operation.

62 IN11 jitter 63 IN12 jitter 64 IN13 jitter 65 IN14 jitter 66 IN15 jitter 67 IN16 jitter 68 OUT9 jitter 69 OUT10 jitter 6A OUT11 jitter 6B OUT12 jitter 6C OUT13 jitter 6D OUT14 jitter 6E OUT15 jitter 6F OUT16 jitter 70 BIPR1 jitter 71 BIPR2 jitter 73 Shut down relay phase generator failure

(phase not changing within 30 minutes) If this indication is on a single CPU card change the CPU card. If all the 3 CPUs show this code then change the communication card.

75 Timer2 input bad RESET the system by pressing RESET button and then BI-OK button in a sequential manner. If problem persists change corresponding CPU card.

78 Data bus check failed 79 EPROM Checksum failed 7A BIPR1 input to GAL stuck at low RESET the system by pressing RESET button and then BI-OK

button in a sequential manner. If problem persists change corresponding CPU card. If the problem still remains change CCC Card. When all CPUs show the code, change CCC.

7B BIPR2 input to GAL stuck at low

7C BIPR1 command output not matching with shutdown relay phase. RESET the system by pressing RESET button and then BI-OK

button in a sequential manner. If problem persists change corresponding CPU card. 7D BIPR1 command output not matching

with shutdown relay phase.



ANNEXURE - D

DETAILS OF QUAD CABLE CONNECTION Details of One Quad Colour:

X

X

XX

A

B

C D

White

Orange

Red Grey

Quad Position in the cable:

X

X

XX

A

B

C D

White

Orange

Red Grey

X

X

XX

A

B

C D

White

Yellow

Red Grey

X

X

XX

A

B

C D

White

Blue

Red Grey

X

X

XX

A

B

C D

White

Black

Red Grey

X

X

XX

A

B

C D

White

Green

Red Grey

X

X

XX

A

B

C D

White

Brown

Red Grey

1

2

3

4

5

6

Pair 1: White & Orange colour i.e. ‘A’ wire and ‘B’ wire of designated colour quad. Pair 2: Red & Grey colour i.e. ‘C’ wire and ‘D’ wire of designated colour quad.

Each Quad is binded by the respective quad colour “BINDER”

1 – ORANGE QUAD 2 -- BLUE QUAD 3 – BROWN QUAD 4 – GREEN QUAD 5 – YELLOW QUAD 6 – BLACK QUAD



Quadding arrangement of cable: Table 1 Colour scheme of PE insulated Quads

Quad Colour

Quad Number

Colour of Conductor Insulation ‘A’ wire ‘B’ wire ‘C’ wire ‘D’ wire

Orange 1 White Orange Red Grey Blue 2 White Blue Red Grey

Brown 3 White Brown Red Grey Green 4 White Green Red Grey Yellow 5 White Yellow Red Grey Black 6 White Black Red Grey

Wire ‘A’ & ‘B’ shall form a pair and ‘C’ & ‘D’ shall form another pair of quad colour. Precautions to be taken during wiring / connections of Axle Counter systems during Installation or maintenance

In a quad of each colour, the designated pair of quad (mentioned in Table I) should be used for circuits.

‘A’ wire & ‘B’ wire : Pair 1 of each colour of quad ‘C’ wire & ‘D’ wire : Pair 2 of each colour of quad

No parallel signaling / other cable should be connected to the quad cable for the circuit operation

If any wire of the pair of quad is broken / non-functional, then use fresh pair of other quad colour

Do not make the two different wires of different quad pairs (colour) for making a pair to run a circuit operational.

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